Subject Code BTTEX05002 Semester Vth
Textile Engineering Department
CTF MPSTME SVKMs NMIMS Shirpur
By Prof P P Kolte
Unit I Carding
Necessity amp Objects of carding Operations involved in carding Fundamental
actions in carding Detail study with construction and working of carding machine
Various sections of carding machine Types of card clothing and their significance and
effects Theories of carding action Analysis of flat actions and carding force
Introduction to Stripping Grinding and Burnishing operations Continuous Feed vs Lap
Feed Various settings of card its influences on carding quality amp production
Unit-II Carding
Transfer mechanism of fibres Consolidation of web into sliver Trumpet amp
Calendar roller condensation Parameters affecting Settings Quality and Production
Concept of draft Types of Draft Distribution of draft Actual and Mechanical draft
Card drive amp calculations related to Efficiency Production of carding machine
Carding faults and their origin waste collection controlling and handling Card
autoleveller Principles Types Advantages and Disadvantages Introduction to
developments in carding
Unit-III Draw frame
Introduction objective of draw frame operating principle Attenuation
(draft) the draft the drafting operation drafting force behavior of the fibres in the
drafting zone friction fields nature and role of fibre friction in drafting distribution of
draft additional effects of draft perfect and real drafting nature of drafting
irregularities coiling- delivery condensing sliver coiling can changing Drafting force
in relation to other parameters- Draft ratio Roller Setting Fibre Crimp sliver density
Roller lapping tendency Selection of creel and web tension draft Monitoring and auto
leveling structure of computerized data collection and monitoring systems waste
collection controlling and handling Production calculations
Unit IV Combing Preparatory
Objects need different types of passages used Preparation for combing
outline operating principles of sliver lap machine ribbon lap machine sliver doubling
machine and super lap machines comparative assessment of web doubling and sliver
doubling processes Systems of lap preparation configuration of fibre feed and its effect
on the quality of product calculation regarding gearing draft production of sliver lap
ribbon lap and super lap machines
Unit-V Combing
Combing Object of combing introduction tasks of comber types of comber
sequence of operation in a rectilinear comber Technology of combing parameters
influencing combing operation- raw material material preparation parallelization of
fibres in the sheet sheet thickness (wt) evenness of the lap sheet disposition of hooks
degree of combing noil percentage and fractionating efficiency of comber
Unit-VI Combing
Combing machines outline classification description of functions- feed feed
of lap sheet feed device nipper assembly cylinder comb top comb take-off amp the
material piecing withdrawal of the web and formation of sliver sliver take-off
drafting arrangement coiling of sliver waste removal (stripping) timing diagram of
comber motions automation in comber Detailed setting of comber machine and gauges
used for setting Gearing drafts and production calculation of combing machine
Text Books
1 Spun yarn technology volume II carding - AVentasubramani
2 Chattopadhyay R and Rengasamay R ldquoSpinning Drawing Combing and Rovingrdquo
NCUTE-Pilot Programme 1999
Reference Book
1 Khare A R ldquoElements of combingrdquo Sai book center Mumbai 1999
2 Khare A R ldquoElements of cardingrdquo Sai book Centre Mumbai 1999
5 Klein W ldquoThe Technology of Short-staple Spinning ldquo The Textile Institute
6 Klein W ldquo A Practical Guide to Opening and Carding ldquo The Textile Institute
8 Technology of Carding ndash R Chattopadhaya NCUTE Publication
Objectives
To have an introduction regarding carding process
To study working of chute feed system
To study advantages and disadvantages of chute feed system
To study various developments in chute feed system
Chute feed is a system of feeding small tufts of cotton fibres
directly from blow room to a series of cards arranged in a circuit
through pneumatic pipe
A condenser in the
pneumatic pipe sucks
the material from blow
room and delivers it to
the flock feeder through
pneumatic pipe by way
of the filling trunk
Fig Flock
Feeder or
Chute Feed
System
The automatic continuous feed directly linked to the blow room
eliminates the lap formation This increases the working efficiency of the
blow room
The main power requirement in doffing the lap weighing
transportation to card and feeding at the card is eliminated
The processing of rejected laps in the blow room is avoided
The fibres are fed to the card in loose sheet form as against
compressed form so that trash particles can be easily extracted from
fibres by the carding action
Excessive sliver irregularities due to the lap licking during high
humidity double lap feeding lap splitting lap piecing etc are
eliminated
When compared to lap fed there is a reduction of 1 CV flock
feeding card sliver
Crushing of foreign materials seed bits and other trash particles during
calendaring and difficulty of removing a subsequent processes is
reduced
Blow room should run the same number of hours per week as the
cards do
The card production must be kept excessive to assure continuous feed
to draw frame at the time of stoppages at blow room due to maintenance
and other unavoidable problems
Chute feed system control short term variation but not the medium
and long term variations
A reliable check on the nominal count can be established in lap
forming system by controlling total lap weight and CV value of the
weight per unit length There is no such control in the chute feeding
system
Change of mixing will result in more waste in chute feed
Necessity
It is always considered by the experts that the card is the heart of the
spinning mill
The statement ldquoWell-carded is half-spunrdquo demonstrate the immense
significance of the carding for the final result of the spinning operation
Carding is an operation where the tuft condition of the fibres is
converted into an individual fibre form
The carding is a very important process because unless the fibres are
separated into individuals they can not be spun into smooth and uniform
yarns neither can they be blended properly with other fibres
Opening to individual fibres
Cleaning
Elimination of dust
Mixing amp Blending
Disentanglement of Neps
Elimination of short fiber
Sliver Formation
Fiber Orientation
Fig Passage of material through carding
- Feed region - Licker-in region - Carding region
- Coiling region - Condensing region
Fig Passage of material through carding
Fig Passage of machine through carding mc
Fig Passage of material through carding
Question
What are the different objectives of the carding
What are the necessities of carding
Enlist the different zones in carding
A well designed feed device is expected to perform the following tasks
Clamp the batt securely over its full width
Be able to hold the material back against the action of the licker-in
Present the batt to the licker-in in such a manner that opening can be
carried out gently
Conventional system
Fig Conventional feed device
1- Feed plate
2- Feed roller
3- Licker-in
4- Mote knife
5- Licker-in undercasing
Fig The shape of the feed plate
a- Guide surface
b- Nose of feed plate
Modern system
The feed roller has a diameter of 80 - 100 mm
Fig Unidirectional feed device
1- Feed plate
2- Feed roller
3- Licker-in
The licker-in
- The greatest part of opening and cleaning is performed by the licker-in
- Cast roller with a diameter usually of around 250 mm
- Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second) a
circumferential speed of around 21 msec
(approximately 76 kmh) and a draft of
more than 1600
Fig The licker-in
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Unit I Carding
Necessity amp Objects of carding Operations involved in carding Fundamental
actions in carding Detail study with construction and working of carding machine
Various sections of carding machine Types of card clothing and their significance and
effects Theories of carding action Analysis of flat actions and carding force
Introduction to Stripping Grinding and Burnishing operations Continuous Feed vs Lap
Feed Various settings of card its influences on carding quality amp production
Unit-II Carding
Transfer mechanism of fibres Consolidation of web into sliver Trumpet amp
Calendar roller condensation Parameters affecting Settings Quality and Production
Concept of draft Types of Draft Distribution of draft Actual and Mechanical draft
Card drive amp calculations related to Efficiency Production of carding machine
Carding faults and their origin waste collection controlling and handling Card
autoleveller Principles Types Advantages and Disadvantages Introduction to
developments in carding
Unit-III Draw frame
Introduction objective of draw frame operating principle Attenuation
(draft) the draft the drafting operation drafting force behavior of the fibres in the
drafting zone friction fields nature and role of fibre friction in drafting distribution of
draft additional effects of draft perfect and real drafting nature of drafting
irregularities coiling- delivery condensing sliver coiling can changing Drafting force
in relation to other parameters- Draft ratio Roller Setting Fibre Crimp sliver density
Roller lapping tendency Selection of creel and web tension draft Monitoring and auto
leveling structure of computerized data collection and monitoring systems waste
collection controlling and handling Production calculations
Unit IV Combing Preparatory
Objects need different types of passages used Preparation for combing
outline operating principles of sliver lap machine ribbon lap machine sliver doubling
machine and super lap machines comparative assessment of web doubling and sliver
doubling processes Systems of lap preparation configuration of fibre feed and its effect
on the quality of product calculation regarding gearing draft production of sliver lap
ribbon lap and super lap machines
Unit-V Combing
Combing Object of combing introduction tasks of comber types of comber
sequence of operation in a rectilinear comber Technology of combing parameters
influencing combing operation- raw material material preparation parallelization of
fibres in the sheet sheet thickness (wt) evenness of the lap sheet disposition of hooks
degree of combing noil percentage and fractionating efficiency of comber
Unit-VI Combing
Combing machines outline classification description of functions- feed feed
of lap sheet feed device nipper assembly cylinder comb top comb take-off amp the
material piecing withdrawal of the web and formation of sliver sliver take-off
drafting arrangement coiling of sliver waste removal (stripping) timing diagram of
comber motions automation in comber Detailed setting of comber machine and gauges
used for setting Gearing drafts and production calculation of combing machine
Text Books
1 Spun yarn technology volume II carding - AVentasubramani
2 Chattopadhyay R and Rengasamay R ldquoSpinning Drawing Combing and Rovingrdquo
NCUTE-Pilot Programme 1999
Reference Book
1 Khare A R ldquoElements of combingrdquo Sai book center Mumbai 1999
2 Khare A R ldquoElements of cardingrdquo Sai book Centre Mumbai 1999
5 Klein W ldquoThe Technology of Short-staple Spinning ldquo The Textile Institute
6 Klein W ldquo A Practical Guide to Opening and Carding ldquo The Textile Institute
8 Technology of Carding ndash R Chattopadhaya NCUTE Publication
Objectives
To have an introduction regarding carding process
To study working of chute feed system
To study advantages and disadvantages of chute feed system
To study various developments in chute feed system
Chute feed is a system of feeding small tufts of cotton fibres
directly from blow room to a series of cards arranged in a circuit
through pneumatic pipe
A condenser in the
pneumatic pipe sucks
the material from blow
room and delivers it to
the flock feeder through
pneumatic pipe by way
of the filling trunk
Fig Flock
Feeder or
Chute Feed
System
The automatic continuous feed directly linked to the blow room
eliminates the lap formation This increases the working efficiency of the
blow room
The main power requirement in doffing the lap weighing
transportation to card and feeding at the card is eliminated
The processing of rejected laps in the blow room is avoided
The fibres are fed to the card in loose sheet form as against
compressed form so that trash particles can be easily extracted from
fibres by the carding action
Excessive sliver irregularities due to the lap licking during high
humidity double lap feeding lap splitting lap piecing etc are
eliminated
When compared to lap fed there is a reduction of 1 CV flock
feeding card sliver
Crushing of foreign materials seed bits and other trash particles during
calendaring and difficulty of removing a subsequent processes is
reduced
Blow room should run the same number of hours per week as the
cards do
The card production must be kept excessive to assure continuous feed
to draw frame at the time of stoppages at blow room due to maintenance
and other unavoidable problems
Chute feed system control short term variation but not the medium
and long term variations
A reliable check on the nominal count can be established in lap
forming system by controlling total lap weight and CV value of the
weight per unit length There is no such control in the chute feeding
system
Change of mixing will result in more waste in chute feed
Necessity
It is always considered by the experts that the card is the heart of the
spinning mill
The statement ldquoWell-carded is half-spunrdquo demonstrate the immense
significance of the carding for the final result of the spinning operation
Carding is an operation where the tuft condition of the fibres is
converted into an individual fibre form
The carding is a very important process because unless the fibres are
separated into individuals they can not be spun into smooth and uniform
yarns neither can they be blended properly with other fibres
Opening to individual fibres
Cleaning
Elimination of dust
Mixing amp Blending
Disentanglement of Neps
Elimination of short fiber
Sliver Formation
Fiber Orientation
Fig Passage of material through carding
- Feed region - Licker-in region - Carding region
- Coiling region - Condensing region
Fig Passage of material through carding
Fig Passage of machine through carding mc
Fig Passage of material through carding
Question
What are the different objectives of the carding
What are the necessities of carding
Enlist the different zones in carding
A well designed feed device is expected to perform the following tasks
Clamp the batt securely over its full width
Be able to hold the material back against the action of the licker-in
Present the batt to the licker-in in such a manner that opening can be
carried out gently
Conventional system
Fig Conventional feed device
1- Feed plate
2- Feed roller
3- Licker-in
4- Mote knife
5- Licker-in undercasing
Fig The shape of the feed plate
a- Guide surface
b- Nose of feed plate
Modern system
The feed roller has a diameter of 80 - 100 mm
Fig Unidirectional feed device
1- Feed plate
2- Feed roller
3- Licker-in
The licker-in
- The greatest part of opening and cleaning is performed by the licker-in
- Cast roller with a diameter usually of around 250 mm
- Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second) a
circumferential speed of around 21 msec
(approximately 76 kmh) and a draft of
more than 1600
Fig The licker-in
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Unit-III Draw frame
Introduction objective of draw frame operating principle Attenuation
(draft) the draft the drafting operation drafting force behavior of the fibres in the
drafting zone friction fields nature and role of fibre friction in drafting distribution of
draft additional effects of draft perfect and real drafting nature of drafting
irregularities coiling- delivery condensing sliver coiling can changing Drafting force
in relation to other parameters- Draft ratio Roller Setting Fibre Crimp sliver density
Roller lapping tendency Selection of creel and web tension draft Monitoring and auto
leveling structure of computerized data collection and monitoring systems waste
collection controlling and handling Production calculations
Unit IV Combing Preparatory
Objects need different types of passages used Preparation for combing
outline operating principles of sliver lap machine ribbon lap machine sliver doubling
machine and super lap machines comparative assessment of web doubling and sliver
doubling processes Systems of lap preparation configuration of fibre feed and its effect
on the quality of product calculation regarding gearing draft production of sliver lap
ribbon lap and super lap machines
Unit-V Combing
Combing Object of combing introduction tasks of comber types of comber
sequence of operation in a rectilinear comber Technology of combing parameters
influencing combing operation- raw material material preparation parallelization of
fibres in the sheet sheet thickness (wt) evenness of the lap sheet disposition of hooks
degree of combing noil percentage and fractionating efficiency of comber
Unit-VI Combing
Combing machines outline classification description of functions- feed feed
of lap sheet feed device nipper assembly cylinder comb top comb take-off amp the
material piecing withdrawal of the web and formation of sliver sliver take-off
drafting arrangement coiling of sliver waste removal (stripping) timing diagram of
comber motions automation in comber Detailed setting of comber machine and gauges
used for setting Gearing drafts and production calculation of combing machine
Text Books
1 Spun yarn technology volume II carding - AVentasubramani
2 Chattopadhyay R and Rengasamay R ldquoSpinning Drawing Combing and Rovingrdquo
NCUTE-Pilot Programme 1999
Reference Book
1 Khare A R ldquoElements of combingrdquo Sai book center Mumbai 1999
2 Khare A R ldquoElements of cardingrdquo Sai book Centre Mumbai 1999
5 Klein W ldquoThe Technology of Short-staple Spinning ldquo The Textile Institute
6 Klein W ldquo A Practical Guide to Opening and Carding ldquo The Textile Institute
8 Technology of Carding ndash R Chattopadhaya NCUTE Publication
Objectives
To have an introduction regarding carding process
To study working of chute feed system
To study advantages and disadvantages of chute feed system
To study various developments in chute feed system
Chute feed is a system of feeding small tufts of cotton fibres
directly from blow room to a series of cards arranged in a circuit
through pneumatic pipe
A condenser in the
pneumatic pipe sucks
the material from blow
room and delivers it to
the flock feeder through
pneumatic pipe by way
of the filling trunk
Fig Flock
Feeder or
Chute Feed
System
The automatic continuous feed directly linked to the blow room
eliminates the lap formation This increases the working efficiency of the
blow room
The main power requirement in doffing the lap weighing
transportation to card and feeding at the card is eliminated
The processing of rejected laps in the blow room is avoided
The fibres are fed to the card in loose sheet form as against
compressed form so that trash particles can be easily extracted from
fibres by the carding action
Excessive sliver irregularities due to the lap licking during high
humidity double lap feeding lap splitting lap piecing etc are
eliminated
When compared to lap fed there is a reduction of 1 CV flock
feeding card sliver
Crushing of foreign materials seed bits and other trash particles during
calendaring and difficulty of removing a subsequent processes is
reduced
Blow room should run the same number of hours per week as the
cards do
The card production must be kept excessive to assure continuous feed
to draw frame at the time of stoppages at blow room due to maintenance
and other unavoidable problems
Chute feed system control short term variation but not the medium
and long term variations
A reliable check on the nominal count can be established in lap
forming system by controlling total lap weight and CV value of the
weight per unit length There is no such control in the chute feeding
system
Change of mixing will result in more waste in chute feed
Necessity
It is always considered by the experts that the card is the heart of the
spinning mill
The statement ldquoWell-carded is half-spunrdquo demonstrate the immense
significance of the carding for the final result of the spinning operation
Carding is an operation where the tuft condition of the fibres is
converted into an individual fibre form
The carding is a very important process because unless the fibres are
separated into individuals they can not be spun into smooth and uniform
yarns neither can they be blended properly with other fibres
Opening to individual fibres
Cleaning
Elimination of dust
Mixing amp Blending
Disentanglement of Neps
Elimination of short fiber
Sliver Formation
Fiber Orientation
Fig Passage of material through carding
- Feed region - Licker-in region - Carding region
- Coiling region - Condensing region
Fig Passage of material through carding
Fig Passage of machine through carding mc
Fig Passage of material through carding
Question
What are the different objectives of the carding
What are the necessities of carding
Enlist the different zones in carding
A well designed feed device is expected to perform the following tasks
Clamp the batt securely over its full width
Be able to hold the material back against the action of the licker-in
Present the batt to the licker-in in such a manner that opening can be
carried out gently
Conventional system
Fig Conventional feed device
1- Feed plate
2- Feed roller
3- Licker-in
4- Mote knife
5- Licker-in undercasing
Fig The shape of the feed plate
a- Guide surface
b- Nose of feed plate
Modern system
The feed roller has a diameter of 80 - 100 mm
Fig Unidirectional feed device
1- Feed plate
2- Feed roller
3- Licker-in
The licker-in
- The greatest part of opening and cleaning is performed by the licker-in
- Cast roller with a diameter usually of around 250 mm
- Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second) a
circumferential speed of around 21 msec
(approximately 76 kmh) and a draft of
more than 1600
Fig The licker-in
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Unit-V Combing
Combing Object of combing introduction tasks of comber types of comber
sequence of operation in a rectilinear comber Technology of combing parameters
influencing combing operation- raw material material preparation parallelization of
fibres in the sheet sheet thickness (wt) evenness of the lap sheet disposition of hooks
degree of combing noil percentage and fractionating efficiency of comber
Unit-VI Combing
Combing machines outline classification description of functions- feed feed
of lap sheet feed device nipper assembly cylinder comb top comb take-off amp the
material piecing withdrawal of the web and formation of sliver sliver take-off
drafting arrangement coiling of sliver waste removal (stripping) timing diagram of
comber motions automation in comber Detailed setting of comber machine and gauges
used for setting Gearing drafts and production calculation of combing machine
Text Books
1 Spun yarn technology volume II carding - AVentasubramani
2 Chattopadhyay R and Rengasamay R ldquoSpinning Drawing Combing and Rovingrdquo
NCUTE-Pilot Programme 1999
Reference Book
1 Khare A R ldquoElements of combingrdquo Sai book center Mumbai 1999
2 Khare A R ldquoElements of cardingrdquo Sai book Centre Mumbai 1999
5 Klein W ldquoThe Technology of Short-staple Spinning ldquo The Textile Institute
6 Klein W ldquo A Practical Guide to Opening and Carding ldquo The Textile Institute
8 Technology of Carding ndash R Chattopadhaya NCUTE Publication
Objectives
To have an introduction regarding carding process
To study working of chute feed system
To study advantages and disadvantages of chute feed system
To study various developments in chute feed system
Chute feed is a system of feeding small tufts of cotton fibres
directly from blow room to a series of cards arranged in a circuit
through pneumatic pipe
A condenser in the
pneumatic pipe sucks
the material from blow
room and delivers it to
the flock feeder through
pneumatic pipe by way
of the filling trunk
Fig Flock
Feeder or
Chute Feed
System
The automatic continuous feed directly linked to the blow room
eliminates the lap formation This increases the working efficiency of the
blow room
The main power requirement in doffing the lap weighing
transportation to card and feeding at the card is eliminated
The processing of rejected laps in the blow room is avoided
The fibres are fed to the card in loose sheet form as against
compressed form so that trash particles can be easily extracted from
fibres by the carding action
Excessive sliver irregularities due to the lap licking during high
humidity double lap feeding lap splitting lap piecing etc are
eliminated
When compared to lap fed there is a reduction of 1 CV flock
feeding card sliver
Crushing of foreign materials seed bits and other trash particles during
calendaring and difficulty of removing a subsequent processes is
reduced
Blow room should run the same number of hours per week as the
cards do
The card production must be kept excessive to assure continuous feed
to draw frame at the time of stoppages at blow room due to maintenance
and other unavoidable problems
Chute feed system control short term variation but not the medium
and long term variations
A reliable check on the nominal count can be established in lap
forming system by controlling total lap weight and CV value of the
weight per unit length There is no such control in the chute feeding
system
Change of mixing will result in more waste in chute feed
Necessity
It is always considered by the experts that the card is the heart of the
spinning mill
The statement ldquoWell-carded is half-spunrdquo demonstrate the immense
significance of the carding for the final result of the spinning operation
Carding is an operation where the tuft condition of the fibres is
converted into an individual fibre form
The carding is a very important process because unless the fibres are
separated into individuals they can not be spun into smooth and uniform
yarns neither can they be blended properly with other fibres
Opening to individual fibres
Cleaning
Elimination of dust
Mixing amp Blending
Disentanglement of Neps
Elimination of short fiber
Sliver Formation
Fiber Orientation
Fig Passage of material through carding
- Feed region - Licker-in region - Carding region
- Coiling region - Condensing region
Fig Passage of material through carding
Fig Passage of machine through carding mc
Fig Passage of material through carding
Question
What are the different objectives of the carding
What are the necessities of carding
Enlist the different zones in carding
A well designed feed device is expected to perform the following tasks
Clamp the batt securely over its full width
Be able to hold the material back against the action of the licker-in
Present the batt to the licker-in in such a manner that opening can be
carried out gently
Conventional system
Fig Conventional feed device
1- Feed plate
2- Feed roller
3- Licker-in
4- Mote knife
5- Licker-in undercasing
Fig The shape of the feed plate
a- Guide surface
b- Nose of feed plate
Modern system
The feed roller has a diameter of 80 - 100 mm
Fig Unidirectional feed device
1- Feed plate
2- Feed roller
3- Licker-in
The licker-in
- The greatest part of opening and cleaning is performed by the licker-in
- Cast roller with a diameter usually of around 250 mm
- Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second) a
circumferential speed of around 21 msec
(approximately 76 kmh) and a draft of
more than 1600
Fig The licker-in
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Text Books
1 Spun yarn technology volume II carding - AVentasubramani
2 Chattopadhyay R and Rengasamay R ldquoSpinning Drawing Combing and Rovingrdquo
NCUTE-Pilot Programme 1999
Reference Book
1 Khare A R ldquoElements of combingrdquo Sai book center Mumbai 1999
2 Khare A R ldquoElements of cardingrdquo Sai book Centre Mumbai 1999
5 Klein W ldquoThe Technology of Short-staple Spinning ldquo The Textile Institute
6 Klein W ldquo A Practical Guide to Opening and Carding ldquo The Textile Institute
8 Technology of Carding ndash R Chattopadhaya NCUTE Publication
Objectives
To have an introduction regarding carding process
To study working of chute feed system
To study advantages and disadvantages of chute feed system
To study various developments in chute feed system
Chute feed is a system of feeding small tufts of cotton fibres
directly from blow room to a series of cards arranged in a circuit
through pneumatic pipe
A condenser in the
pneumatic pipe sucks
the material from blow
room and delivers it to
the flock feeder through
pneumatic pipe by way
of the filling trunk
Fig Flock
Feeder or
Chute Feed
System
The automatic continuous feed directly linked to the blow room
eliminates the lap formation This increases the working efficiency of the
blow room
The main power requirement in doffing the lap weighing
transportation to card and feeding at the card is eliminated
The processing of rejected laps in the blow room is avoided
The fibres are fed to the card in loose sheet form as against
compressed form so that trash particles can be easily extracted from
fibres by the carding action
Excessive sliver irregularities due to the lap licking during high
humidity double lap feeding lap splitting lap piecing etc are
eliminated
When compared to lap fed there is a reduction of 1 CV flock
feeding card sliver
Crushing of foreign materials seed bits and other trash particles during
calendaring and difficulty of removing a subsequent processes is
reduced
Blow room should run the same number of hours per week as the
cards do
The card production must be kept excessive to assure continuous feed
to draw frame at the time of stoppages at blow room due to maintenance
and other unavoidable problems
Chute feed system control short term variation but not the medium
and long term variations
A reliable check on the nominal count can be established in lap
forming system by controlling total lap weight and CV value of the
weight per unit length There is no such control in the chute feeding
system
Change of mixing will result in more waste in chute feed
Necessity
It is always considered by the experts that the card is the heart of the
spinning mill
The statement ldquoWell-carded is half-spunrdquo demonstrate the immense
significance of the carding for the final result of the spinning operation
Carding is an operation where the tuft condition of the fibres is
converted into an individual fibre form
The carding is a very important process because unless the fibres are
separated into individuals they can not be spun into smooth and uniform
yarns neither can they be blended properly with other fibres
Opening to individual fibres
Cleaning
Elimination of dust
Mixing amp Blending
Disentanglement of Neps
Elimination of short fiber
Sliver Formation
Fiber Orientation
Fig Passage of material through carding
- Feed region - Licker-in region - Carding region
- Coiling region - Condensing region
Fig Passage of material through carding
Fig Passage of machine through carding mc
Fig Passage of material through carding
Question
What are the different objectives of the carding
What are the necessities of carding
Enlist the different zones in carding
A well designed feed device is expected to perform the following tasks
Clamp the batt securely over its full width
Be able to hold the material back against the action of the licker-in
Present the batt to the licker-in in such a manner that opening can be
carried out gently
Conventional system
Fig Conventional feed device
1- Feed plate
2- Feed roller
3- Licker-in
4- Mote knife
5- Licker-in undercasing
Fig The shape of the feed plate
a- Guide surface
b- Nose of feed plate
Modern system
The feed roller has a diameter of 80 - 100 mm
Fig Unidirectional feed device
1- Feed plate
2- Feed roller
3- Licker-in
The licker-in
- The greatest part of opening and cleaning is performed by the licker-in
- Cast roller with a diameter usually of around 250 mm
- Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second) a
circumferential speed of around 21 msec
(approximately 76 kmh) and a draft of
more than 1600
Fig The licker-in
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Objectives
To have an introduction regarding carding process
To study working of chute feed system
To study advantages and disadvantages of chute feed system
To study various developments in chute feed system
Chute feed is a system of feeding small tufts of cotton fibres
directly from blow room to a series of cards arranged in a circuit
through pneumatic pipe
A condenser in the
pneumatic pipe sucks
the material from blow
room and delivers it to
the flock feeder through
pneumatic pipe by way
of the filling trunk
Fig Flock
Feeder or
Chute Feed
System
The automatic continuous feed directly linked to the blow room
eliminates the lap formation This increases the working efficiency of the
blow room
The main power requirement in doffing the lap weighing
transportation to card and feeding at the card is eliminated
The processing of rejected laps in the blow room is avoided
The fibres are fed to the card in loose sheet form as against
compressed form so that trash particles can be easily extracted from
fibres by the carding action
Excessive sliver irregularities due to the lap licking during high
humidity double lap feeding lap splitting lap piecing etc are
eliminated
When compared to lap fed there is a reduction of 1 CV flock
feeding card sliver
Crushing of foreign materials seed bits and other trash particles during
calendaring and difficulty of removing a subsequent processes is
reduced
Blow room should run the same number of hours per week as the
cards do
The card production must be kept excessive to assure continuous feed
to draw frame at the time of stoppages at blow room due to maintenance
and other unavoidable problems
Chute feed system control short term variation but not the medium
and long term variations
A reliable check on the nominal count can be established in lap
forming system by controlling total lap weight and CV value of the
weight per unit length There is no such control in the chute feeding
system
Change of mixing will result in more waste in chute feed
Necessity
It is always considered by the experts that the card is the heart of the
spinning mill
The statement ldquoWell-carded is half-spunrdquo demonstrate the immense
significance of the carding for the final result of the spinning operation
Carding is an operation where the tuft condition of the fibres is
converted into an individual fibre form
The carding is a very important process because unless the fibres are
separated into individuals they can not be spun into smooth and uniform
yarns neither can they be blended properly with other fibres
Opening to individual fibres
Cleaning
Elimination of dust
Mixing amp Blending
Disentanglement of Neps
Elimination of short fiber
Sliver Formation
Fiber Orientation
Fig Passage of material through carding
- Feed region - Licker-in region - Carding region
- Coiling region - Condensing region
Fig Passage of material through carding
Fig Passage of machine through carding mc
Fig Passage of material through carding
Question
What are the different objectives of the carding
What are the necessities of carding
Enlist the different zones in carding
A well designed feed device is expected to perform the following tasks
Clamp the batt securely over its full width
Be able to hold the material back against the action of the licker-in
Present the batt to the licker-in in such a manner that opening can be
carried out gently
Conventional system
Fig Conventional feed device
1- Feed plate
2- Feed roller
3- Licker-in
4- Mote knife
5- Licker-in undercasing
Fig The shape of the feed plate
a- Guide surface
b- Nose of feed plate
Modern system
The feed roller has a diameter of 80 - 100 mm
Fig Unidirectional feed device
1- Feed plate
2- Feed roller
3- Licker-in
The licker-in
- The greatest part of opening and cleaning is performed by the licker-in
- Cast roller with a diameter usually of around 250 mm
- Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second) a
circumferential speed of around 21 msec
(approximately 76 kmh) and a draft of
more than 1600
Fig The licker-in
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Chute feed is a system of feeding small tufts of cotton fibres
directly from blow room to a series of cards arranged in a circuit
through pneumatic pipe
A condenser in the
pneumatic pipe sucks
the material from blow
room and delivers it to
the flock feeder through
pneumatic pipe by way
of the filling trunk
Fig Flock
Feeder or
Chute Feed
System
The automatic continuous feed directly linked to the blow room
eliminates the lap formation This increases the working efficiency of the
blow room
The main power requirement in doffing the lap weighing
transportation to card and feeding at the card is eliminated
The processing of rejected laps in the blow room is avoided
The fibres are fed to the card in loose sheet form as against
compressed form so that trash particles can be easily extracted from
fibres by the carding action
Excessive sliver irregularities due to the lap licking during high
humidity double lap feeding lap splitting lap piecing etc are
eliminated
When compared to lap fed there is a reduction of 1 CV flock
feeding card sliver
Crushing of foreign materials seed bits and other trash particles during
calendaring and difficulty of removing a subsequent processes is
reduced
Blow room should run the same number of hours per week as the
cards do
The card production must be kept excessive to assure continuous feed
to draw frame at the time of stoppages at blow room due to maintenance
and other unavoidable problems
Chute feed system control short term variation but not the medium
and long term variations
A reliable check on the nominal count can be established in lap
forming system by controlling total lap weight and CV value of the
weight per unit length There is no such control in the chute feeding
system
Change of mixing will result in more waste in chute feed
Necessity
It is always considered by the experts that the card is the heart of the
spinning mill
The statement ldquoWell-carded is half-spunrdquo demonstrate the immense
significance of the carding for the final result of the spinning operation
Carding is an operation where the tuft condition of the fibres is
converted into an individual fibre form
The carding is a very important process because unless the fibres are
separated into individuals they can not be spun into smooth and uniform
yarns neither can they be blended properly with other fibres
Opening to individual fibres
Cleaning
Elimination of dust
Mixing amp Blending
Disentanglement of Neps
Elimination of short fiber
Sliver Formation
Fiber Orientation
Fig Passage of material through carding
- Feed region - Licker-in region - Carding region
- Coiling region - Condensing region
Fig Passage of material through carding
Fig Passage of machine through carding mc
Fig Passage of material through carding
Question
What are the different objectives of the carding
What are the necessities of carding
Enlist the different zones in carding
A well designed feed device is expected to perform the following tasks
Clamp the batt securely over its full width
Be able to hold the material back against the action of the licker-in
Present the batt to the licker-in in such a manner that opening can be
carried out gently
Conventional system
Fig Conventional feed device
1- Feed plate
2- Feed roller
3- Licker-in
4- Mote knife
5- Licker-in undercasing
Fig The shape of the feed plate
a- Guide surface
b- Nose of feed plate
Modern system
The feed roller has a diameter of 80 - 100 mm
Fig Unidirectional feed device
1- Feed plate
2- Feed roller
3- Licker-in
The licker-in
- The greatest part of opening and cleaning is performed by the licker-in
- Cast roller with a diameter usually of around 250 mm
- Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second) a
circumferential speed of around 21 msec
(approximately 76 kmh) and a draft of
more than 1600
Fig The licker-in
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
A condenser in the
pneumatic pipe sucks
the material from blow
room and delivers it to
the flock feeder through
pneumatic pipe by way
of the filling trunk
Fig Flock
Feeder or
Chute Feed
System
The automatic continuous feed directly linked to the blow room
eliminates the lap formation This increases the working efficiency of the
blow room
The main power requirement in doffing the lap weighing
transportation to card and feeding at the card is eliminated
The processing of rejected laps in the blow room is avoided
The fibres are fed to the card in loose sheet form as against
compressed form so that trash particles can be easily extracted from
fibres by the carding action
Excessive sliver irregularities due to the lap licking during high
humidity double lap feeding lap splitting lap piecing etc are
eliminated
When compared to lap fed there is a reduction of 1 CV flock
feeding card sliver
Crushing of foreign materials seed bits and other trash particles during
calendaring and difficulty of removing a subsequent processes is
reduced
Blow room should run the same number of hours per week as the
cards do
The card production must be kept excessive to assure continuous feed
to draw frame at the time of stoppages at blow room due to maintenance
and other unavoidable problems
Chute feed system control short term variation but not the medium
and long term variations
A reliable check on the nominal count can be established in lap
forming system by controlling total lap weight and CV value of the
weight per unit length There is no such control in the chute feeding
system
Change of mixing will result in more waste in chute feed
Necessity
It is always considered by the experts that the card is the heart of the
spinning mill
The statement ldquoWell-carded is half-spunrdquo demonstrate the immense
significance of the carding for the final result of the spinning operation
Carding is an operation where the tuft condition of the fibres is
converted into an individual fibre form
The carding is a very important process because unless the fibres are
separated into individuals they can not be spun into smooth and uniform
yarns neither can they be blended properly with other fibres
Opening to individual fibres
Cleaning
Elimination of dust
Mixing amp Blending
Disentanglement of Neps
Elimination of short fiber
Sliver Formation
Fiber Orientation
Fig Passage of material through carding
- Feed region - Licker-in region - Carding region
- Coiling region - Condensing region
Fig Passage of material through carding
Fig Passage of machine through carding mc
Fig Passage of material through carding
Question
What are the different objectives of the carding
What are the necessities of carding
Enlist the different zones in carding
A well designed feed device is expected to perform the following tasks
Clamp the batt securely over its full width
Be able to hold the material back against the action of the licker-in
Present the batt to the licker-in in such a manner that opening can be
carried out gently
Conventional system
Fig Conventional feed device
1- Feed plate
2- Feed roller
3- Licker-in
4- Mote knife
5- Licker-in undercasing
Fig The shape of the feed plate
a- Guide surface
b- Nose of feed plate
Modern system
The feed roller has a diameter of 80 - 100 mm
Fig Unidirectional feed device
1- Feed plate
2- Feed roller
3- Licker-in
The licker-in
- The greatest part of opening and cleaning is performed by the licker-in
- Cast roller with a diameter usually of around 250 mm
- Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second) a
circumferential speed of around 21 msec
(approximately 76 kmh) and a draft of
more than 1600
Fig The licker-in
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
The automatic continuous feed directly linked to the blow room
eliminates the lap formation This increases the working efficiency of the
blow room
The main power requirement in doffing the lap weighing
transportation to card and feeding at the card is eliminated
The processing of rejected laps in the blow room is avoided
The fibres are fed to the card in loose sheet form as against
compressed form so that trash particles can be easily extracted from
fibres by the carding action
Excessive sliver irregularities due to the lap licking during high
humidity double lap feeding lap splitting lap piecing etc are
eliminated
When compared to lap fed there is a reduction of 1 CV flock
feeding card sliver
Crushing of foreign materials seed bits and other trash particles during
calendaring and difficulty of removing a subsequent processes is
reduced
Blow room should run the same number of hours per week as the
cards do
The card production must be kept excessive to assure continuous feed
to draw frame at the time of stoppages at blow room due to maintenance
and other unavoidable problems
Chute feed system control short term variation but not the medium
and long term variations
A reliable check on the nominal count can be established in lap
forming system by controlling total lap weight and CV value of the
weight per unit length There is no such control in the chute feeding
system
Change of mixing will result in more waste in chute feed
Necessity
It is always considered by the experts that the card is the heart of the
spinning mill
The statement ldquoWell-carded is half-spunrdquo demonstrate the immense
significance of the carding for the final result of the spinning operation
Carding is an operation where the tuft condition of the fibres is
converted into an individual fibre form
The carding is a very important process because unless the fibres are
separated into individuals they can not be spun into smooth and uniform
yarns neither can they be blended properly with other fibres
Opening to individual fibres
Cleaning
Elimination of dust
Mixing amp Blending
Disentanglement of Neps
Elimination of short fiber
Sliver Formation
Fiber Orientation
Fig Passage of material through carding
- Feed region - Licker-in region - Carding region
- Coiling region - Condensing region
Fig Passage of material through carding
Fig Passage of machine through carding mc
Fig Passage of material through carding
Question
What are the different objectives of the carding
What are the necessities of carding
Enlist the different zones in carding
A well designed feed device is expected to perform the following tasks
Clamp the batt securely over its full width
Be able to hold the material back against the action of the licker-in
Present the batt to the licker-in in such a manner that opening can be
carried out gently
Conventional system
Fig Conventional feed device
1- Feed plate
2- Feed roller
3- Licker-in
4- Mote knife
5- Licker-in undercasing
Fig The shape of the feed plate
a- Guide surface
b- Nose of feed plate
Modern system
The feed roller has a diameter of 80 - 100 mm
Fig Unidirectional feed device
1- Feed plate
2- Feed roller
3- Licker-in
The licker-in
- The greatest part of opening and cleaning is performed by the licker-in
- Cast roller with a diameter usually of around 250 mm
- Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second) a
circumferential speed of around 21 msec
(approximately 76 kmh) and a draft of
more than 1600
Fig The licker-in
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Excessive sliver irregularities due to the lap licking during high
humidity double lap feeding lap splitting lap piecing etc are
eliminated
When compared to lap fed there is a reduction of 1 CV flock
feeding card sliver
Crushing of foreign materials seed bits and other trash particles during
calendaring and difficulty of removing a subsequent processes is
reduced
Blow room should run the same number of hours per week as the
cards do
The card production must be kept excessive to assure continuous feed
to draw frame at the time of stoppages at blow room due to maintenance
and other unavoidable problems
Chute feed system control short term variation but not the medium
and long term variations
A reliable check on the nominal count can be established in lap
forming system by controlling total lap weight and CV value of the
weight per unit length There is no such control in the chute feeding
system
Change of mixing will result in more waste in chute feed
Necessity
It is always considered by the experts that the card is the heart of the
spinning mill
The statement ldquoWell-carded is half-spunrdquo demonstrate the immense
significance of the carding for the final result of the spinning operation
Carding is an operation where the tuft condition of the fibres is
converted into an individual fibre form
The carding is a very important process because unless the fibres are
separated into individuals they can not be spun into smooth and uniform
yarns neither can they be blended properly with other fibres
Opening to individual fibres
Cleaning
Elimination of dust
Mixing amp Blending
Disentanglement of Neps
Elimination of short fiber
Sliver Formation
Fiber Orientation
Fig Passage of material through carding
- Feed region - Licker-in region - Carding region
- Coiling region - Condensing region
Fig Passage of material through carding
Fig Passage of machine through carding mc
Fig Passage of material through carding
Question
What are the different objectives of the carding
What are the necessities of carding
Enlist the different zones in carding
A well designed feed device is expected to perform the following tasks
Clamp the batt securely over its full width
Be able to hold the material back against the action of the licker-in
Present the batt to the licker-in in such a manner that opening can be
carried out gently
Conventional system
Fig Conventional feed device
1- Feed plate
2- Feed roller
3- Licker-in
4- Mote knife
5- Licker-in undercasing
Fig The shape of the feed plate
a- Guide surface
b- Nose of feed plate
Modern system
The feed roller has a diameter of 80 - 100 mm
Fig Unidirectional feed device
1- Feed plate
2- Feed roller
3- Licker-in
The licker-in
- The greatest part of opening and cleaning is performed by the licker-in
- Cast roller with a diameter usually of around 250 mm
- Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second) a
circumferential speed of around 21 msec
(approximately 76 kmh) and a draft of
more than 1600
Fig The licker-in
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Blow room should run the same number of hours per week as the
cards do
The card production must be kept excessive to assure continuous feed
to draw frame at the time of stoppages at blow room due to maintenance
and other unavoidable problems
Chute feed system control short term variation but not the medium
and long term variations
A reliable check on the nominal count can be established in lap
forming system by controlling total lap weight and CV value of the
weight per unit length There is no such control in the chute feeding
system
Change of mixing will result in more waste in chute feed
Necessity
It is always considered by the experts that the card is the heart of the
spinning mill
The statement ldquoWell-carded is half-spunrdquo demonstrate the immense
significance of the carding for the final result of the spinning operation
Carding is an operation where the tuft condition of the fibres is
converted into an individual fibre form
The carding is a very important process because unless the fibres are
separated into individuals they can not be spun into smooth and uniform
yarns neither can they be blended properly with other fibres
Opening to individual fibres
Cleaning
Elimination of dust
Mixing amp Blending
Disentanglement of Neps
Elimination of short fiber
Sliver Formation
Fiber Orientation
Fig Passage of material through carding
- Feed region - Licker-in region - Carding region
- Coiling region - Condensing region
Fig Passage of material through carding
Fig Passage of machine through carding mc
Fig Passage of material through carding
Question
What are the different objectives of the carding
What are the necessities of carding
Enlist the different zones in carding
A well designed feed device is expected to perform the following tasks
Clamp the batt securely over its full width
Be able to hold the material back against the action of the licker-in
Present the batt to the licker-in in such a manner that opening can be
carried out gently
Conventional system
Fig Conventional feed device
1- Feed plate
2- Feed roller
3- Licker-in
4- Mote knife
5- Licker-in undercasing
Fig The shape of the feed plate
a- Guide surface
b- Nose of feed plate
Modern system
The feed roller has a diameter of 80 - 100 mm
Fig Unidirectional feed device
1- Feed plate
2- Feed roller
3- Licker-in
The licker-in
- The greatest part of opening and cleaning is performed by the licker-in
- Cast roller with a diameter usually of around 250 mm
- Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second) a
circumferential speed of around 21 msec
(approximately 76 kmh) and a draft of
more than 1600
Fig The licker-in
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Necessity
It is always considered by the experts that the card is the heart of the
spinning mill
The statement ldquoWell-carded is half-spunrdquo demonstrate the immense
significance of the carding for the final result of the spinning operation
Carding is an operation where the tuft condition of the fibres is
converted into an individual fibre form
The carding is a very important process because unless the fibres are
separated into individuals they can not be spun into smooth and uniform
yarns neither can they be blended properly with other fibres
Opening to individual fibres
Cleaning
Elimination of dust
Mixing amp Blending
Disentanglement of Neps
Elimination of short fiber
Sliver Formation
Fiber Orientation
Fig Passage of material through carding
- Feed region - Licker-in region - Carding region
- Coiling region - Condensing region
Fig Passage of material through carding
Fig Passage of machine through carding mc
Fig Passage of material through carding
Question
What are the different objectives of the carding
What are the necessities of carding
Enlist the different zones in carding
A well designed feed device is expected to perform the following tasks
Clamp the batt securely over its full width
Be able to hold the material back against the action of the licker-in
Present the batt to the licker-in in such a manner that opening can be
carried out gently
Conventional system
Fig Conventional feed device
1- Feed plate
2- Feed roller
3- Licker-in
4- Mote knife
5- Licker-in undercasing
Fig The shape of the feed plate
a- Guide surface
b- Nose of feed plate
Modern system
The feed roller has a diameter of 80 - 100 mm
Fig Unidirectional feed device
1- Feed plate
2- Feed roller
3- Licker-in
The licker-in
- The greatest part of opening and cleaning is performed by the licker-in
- Cast roller with a diameter usually of around 250 mm
- Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second) a
circumferential speed of around 21 msec
(approximately 76 kmh) and a draft of
more than 1600
Fig The licker-in
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Opening to individual fibres
Cleaning
Elimination of dust
Mixing amp Blending
Disentanglement of Neps
Elimination of short fiber
Sliver Formation
Fiber Orientation
Fig Passage of material through carding
- Feed region - Licker-in region - Carding region
- Coiling region - Condensing region
Fig Passage of material through carding
Fig Passage of machine through carding mc
Fig Passage of material through carding
Question
What are the different objectives of the carding
What are the necessities of carding
Enlist the different zones in carding
A well designed feed device is expected to perform the following tasks
Clamp the batt securely over its full width
Be able to hold the material back against the action of the licker-in
Present the batt to the licker-in in such a manner that opening can be
carried out gently
Conventional system
Fig Conventional feed device
1- Feed plate
2- Feed roller
3- Licker-in
4- Mote knife
5- Licker-in undercasing
Fig The shape of the feed plate
a- Guide surface
b- Nose of feed plate
Modern system
The feed roller has a diameter of 80 - 100 mm
Fig Unidirectional feed device
1- Feed plate
2- Feed roller
3- Licker-in
The licker-in
- The greatest part of opening and cleaning is performed by the licker-in
- Cast roller with a diameter usually of around 250 mm
- Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second) a
circumferential speed of around 21 msec
(approximately 76 kmh) and a draft of
more than 1600
Fig The licker-in
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Fig Passage of material through carding
- Feed region - Licker-in region - Carding region
- Coiling region - Condensing region
Fig Passage of material through carding
Fig Passage of machine through carding mc
Fig Passage of material through carding
Question
What are the different objectives of the carding
What are the necessities of carding
Enlist the different zones in carding
A well designed feed device is expected to perform the following tasks
Clamp the batt securely over its full width
Be able to hold the material back against the action of the licker-in
Present the batt to the licker-in in such a manner that opening can be
carried out gently
Conventional system
Fig Conventional feed device
1- Feed plate
2- Feed roller
3- Licker-in
4- Mote knife
5- Licker-in undercasing
Fig The shape of the feed plate
a- Guide surface
b- Nose of feed plate
Modern system
The feed roller has a diameter of 80 - 100 mm
Fig Unidirectional feed device
1- Feed plate
2- Feed roller
3- Licker-in
The licker-in
- The greatest part of opening and cleaning is performed by the licker-in
- Cast roller with a diameter usually of around 250 mm
- Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second) a
circumferential speed of around 21 msec
(approximately 76 kmh) and a draft of
more than 1600
Fig The licker-in
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
- Feed region - Licker-in region - Carding region
- Coiling region - Condensing region
Fig Passage of material through carding
Fig Passage of machine through carding mc
Fig Passage of material through carding
Question
What are the different objectives of the carding
What are the necessities of carding
Enlist the different zones in carding
A well designed feed device is expected to perform the following tasks
Clamp the batt securely over its full width
Be able to hold the material back against the action of the licker-in
Present the batt to the licker-in in such a manner that opening can be
carried out gently
Conventional system
Fig Conventional feed device
1- Feed plate
2- Feed roller
3- Licker-in
4- Mote knife
5- Licker-in undercasing
Fig The shape of the feed plate
a- Guide surface
b- Nose of feed plate
Modern system
The feed roller has a diameter of 80 - 100 mm
Fig Unidirectional feed device
1- Feed plate
2- Feed roller
3- Licker-in
The licker-in
- The greatest part of opening and cleaning is performed by the licker-in
- Cast roller with a diameter usually of around 250 mm
- Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second) a
circumferential speed of around 21 msec
(approximately 76 kmh) and a draft of
more than 1600
Fig The licker-in
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Fig Passage of material through carding
Question
What are the different objectives of the carding
What are the necessities of carding
Enlist the different zones in carding
A well designed feed device is expected to perform the following tasks
Clamp the batt securely over its full width
Be able to hold the material back against the action of the licker-in
Present the batt to the licker-in in such a manner that opening can be
carried out gently
Conventional system
Fig Conventional feed device
1- Feed plate
2- Feed roller
3- Licker-in
4- Mote knife
5- Licker-in undercasing
Fig The shape of the feed plate
a- Guide surface
b- Nose of feed plate
Modern system
The feed roller has a diameter of 80 - 100 mm
Fig Unidirectional feed device
1- Feed plate
2- Feed roller
3- Licker-in
The licker-in
- The greatest part of opening and cleaning is performed by the licker-in
- Cast roller with a diameter usually of around 250 mm
- Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second) a
circumferential speed of around 21 msec
(approximately 76 kmh) and a draft of
more than 1600
Fig The licker-in
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Question
What are the different objectives of the carding
What are the necessities of carding
Enlist the different zones in carding
A well designed feed device is expected to perform the following tasks
Clamp the batt securely over its full width
Be able to hold the material back against the action of the licker-in
Present the batt to the licker-in in such a manner that opening can be
carried out gently
Conventional system
Fig Conventional feed device
1- Feed plate
2- Feed roller
3- Licker-in
4- Mote knife
5- Licker-in undercasing
Fig The shape of the feed plate
a- Guide surface
b- Nose of feed plate
Modern system
The feed roller has a diameter of 80 - 100 mm
Fig Unidirectional feed device
1- Feed plate
2- Feed roller
3- Licker-in
The licker-in
- The greatest part of opening and cleaning is performed by the licker-in
- Cast roller with a diameter usually of around 250 mm
- Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second) a
circumferential speed of around 21 msec
(approximately 76 kmh) and a draft of
more than 1600
Fig The licker-in
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
A well designed feed device is expected to perform the following tasks
Clamp the batt securely over its full width
Be able to hold the material back against the action of the licker-in
Present the batt to the licker-in in such a manner that opening can be
carried out gently
Conventional system
Fig Conventional feed device
1- Feed plate
2- Feed roller
3- Licker-in
4- Mote knife
5- Licker-in undercasing
Fig The shape of the feed plate
a- Guide surface
b- Nose of feed plate
Modern system
The feed roller has a diameter of 80 - 100 mm
Fig Unidirectional feed device
1- Feed plate
2- Feed roller
3- Licker-in
The licker-in
- The greatest part of opening and cleaning is performed by the licker-in
- Cast roller with a diameter usually of around 250 mm
- Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second) a
circumferential speed of around 21 msec
(approximately 76 kmh) and a draft of
more than 1600
Fig The licker-in
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Conventional system
Fig Conventional feed device
1- Feed plate
2- Feed roller
3- Licker-in
4- Mote knife
5- Licker-in undercasing
Fig The shape of the feed plate
a- Guide surface
b- Nose of feed plate
Modern system
The feed roller has a diameter of 80 - 100 mm
Fig Unidirectional feed device
1- Feed plate
2- Feed roller
3- Licker-in
The licker-in
- The greatest part of opening and cleaning is performed by the licker-in
- Cast roller with a diameter usually of around 250 mm
- Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second) a
circumferential speed of around 21 msec
(approximately 76 kmh) and a draft of
more than 1600
Fig The licker-in
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Modern system
The feed roller has a diameter of 80 - 100 mm
Fig Unidirectional feed device
1- Feed plate
2- Feed roller
3- Licker-in
The licker-in
- The greatest part of opening and cleaning is performed by the licker-in
- Cast roller with a diameter usually of around 250 mm
- Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second) a
circumferential speed of around 21 msec
(approximately 76 kmh) and a draft of
more than 1600
Fig The licker-in
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
The licker-in
- The greatest part of opening and cleaning is performed by the licker-in
- Cast roller with a diameter usually of around 250 mm
- Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second) a
circumferential speed of around 21 msec
(approximately 76 kmh) and a draft of
more than 1600
Fig The licker-in
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Degree of deterioration can and must be precisely controlled by
adjustment of
the thickness of the batt
the degree of openness of the raw material in the feed-stock
the spacing between the operating devices
the degree of orientation of the fibers in the feedstock
the aggressiveness of the clothing
the rotation speed of the licker-in
the material throughput
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Elimination of waste
The cleaning assembly consisted of 1-2 mote knives and a grid one
half of which was made of slotted sheet and another half of perforated sheet
1- Licker-in
2- Mote knife
3- Carding plate
3a- Special clothing
4- Grid with carding segment
5- Licker-in cover
Fig Carding segments under the licker-in of the Rieter C 51 card
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Function
Opening of tufts into individual fibers
Elimination of remaining impurities
Elimination of some of the short fibers
Untangling neps (possibly their elimination)
Dust removal
High degree of longitudinal orientation of the fibers
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Main cylinder
- The cylinder is usually manufactured from cast iron but is now
sometimes made of steel
- Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm
-The roundness tolerance must be maintained within extremely tight
limits ndash the narrowest setting distance (between the cylinder and the
doffer) is only about 01 mm
-The cylinder is generally supported in roller bearings
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Flats
- Altogether 100 - 120 flats
- The bars of the flats are made of cast iron (nowadays aluminum profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
Fig A modern flat construction Fig Dirt take-up of the flats
from the entry point
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Carding plates instead of flats
Stationary carding plates were used for a short time as carding
elements in place of traveling flats
Fig Carding plates instead of flats C1 C2 C3 C4
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
In carding mc two basic actions are taking place bn two wire
covered surfaces these are
1 Carding action
2 Stripping action
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
The separation of fibres from tuft held in bn two wire surfaces is called
carding action
Following conditions
1] There should be two very closely placed (03mm or 20-30 times
dia of fibre) wire covered surfaces
2] Wire points on it should face each other ie
point to point arrangement
3] Interaction surfaces should move either in
opposite direction or in same direction
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
The process of fibre transfer from one surface to another is called
stripping
Necessary conditions ndash
- Two wire covered surfaces facing each other
- The distance bn them should be around 03mm or less ( 20 to
30 times the dia of fibre)
- One surface should face back of wire from each other ie point
to back arrangement
- Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting bn wire points
- The relative surface speed of the wire clothed surface
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer
(2) Stripping the fibre web from the doffer
(3) Gathering the fibre web into a twist less strand (sliver)
(4) Condensing or calendering the sliver
(5) Depositing the sliver into the sliver can
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
The doffer
-The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm (680 mm on Rieter machines)
- It is fitted with metallic clothing and runs
at speeds up to about 300 mmin
Fig Clothing configuration between
main cylinder and doffer
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Detaching
- On old cards a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer
- A roller (Fig 1161) now has the task of separating the web from the
doffer
Fig Web detaching using detaching rollers and transverse belts
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Condensing web into sliver
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Fig Condensor
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
- The sliver must be coiled in cans for storage and transport
- Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm
Fig Can filling device (coiler) Fig Laying down sliver in cans
R - Rotating plate
L - Guide passage
D - The delivery cylinders
C - The turntable can plate
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
A main drive for the cylinder licker-in and
flats
B drive for the infeed
C drive for the delivery ie doffer
detaching rollers and coiler
D drive for the cleaning roller of the
detaching roller
E drive for the cleaning roller of the flats
via the strip-ping roller
F fan
Several manufacturers eg Rieter
also provide a separate drive for the flats
Individual drives have the advantage that
transmission of the forces is better and
adjustments can be performed more quickly
and conveniently They are also better suited
to operation with control equipment
Fig Drive of a
modern card
(Truumltzschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Choice of clothing
The clothing has the greatest influence on quality and productivity
Selection criteria are
Type and design of card
Rotation speed of the cylinder
Production rate
Material throughput
Raw material type (natural or man-made fibers)
Fiber characteristics (mainly fineness length bulk dirt content)
Overall quality requirements
Price of the clothing
Service offered by the clothing supplier
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Classification of card clothing
1Flexible clothings
2Semi-rigid clothings
3Metallic clothings
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Flexible clothing
- Here hooks of round or oval wire set into elastic multiple-ply cloth
backings
- Each hook is bent to a U- shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed
-In the flats the point density is in the range of 240-500 pointsinch
Fig Flexible clothing
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Semi-rigid Clothing
bull Here flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings
bull More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee
bull These are found in flats
Fig Semi-rigid Clothing
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Metallic Clothing
In manufacturing process a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth
This thin portion is stamped or punched so as to get thin serrated strip
called as saw tooth wire
These are found in licker-in main cylinder and doffer
Fig Forming the wire profile for metallic clothing
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Metallic wire on cylinder amp Doffer
bull In comparison to the licker-in wire metallic wire on cylinder amp doffer
are much finer
bull The cylinder wire are much smaller in size compared to doffer wire
bull The pointsinch on cylinder wire are higher than the doffer wire
bull The thickness of the rib for doffer wire is more than that for cylinder
wire
bull The angle of leading edge for cylinder wire is more than that for doffer
wire
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
bull The conventional carding efficiency is vary much effected due to
frequent stoppages for stripping and grinding
bull Further the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste and neps
formation
bull Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed so cannot be run at high speed
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
bull Reduction in stripping cycles-once in 2 or 3 days
bull No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis
bull More production amp regularity of sliver is improved amp labour work is
reduced
bull NO neps formation due to better wire condition
bull Saving of good fibres Lesser variation in card sliver owing to reduced
stripping cycles
bull Card can run at high speed owing to rigid foundation of wires
bull Economic in long run
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
bull Less fibre holding power
bull It shows slightly higher fibre damage
bull High fly generation
bull Requires higher power consumption
bull Greater care in maintenance and attention owing closer gauging and
setting
bull It is difficult to replace the damaged wire portion only (Damaged
portion only can be replaced in flexible fillet clothing)
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Necessity of stripping
bull During the carding process fibres and impurities become embedded in
the wires of the flats cylinder amp doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver amp
finally affect the quality of the yarn
bull So stripping the dust fibres amp impurities from the card clothing is
essential to regain their efficiency
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Stripping Roller This is a wooden roller mounted on steel shaft covered
with flexible wire fillet The roller is about 6 inch in dia and slightly
longer than the width of the cylinder
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
bull It has serious disadvantages of throwing a considerable amount of dustamp fly
from card clothing into the card room atmosphere
bull There by creating undesirable and unhealthy working condition amp spoils the
machinery and product
Developments of stripping
Following are some of the developments of stripping
method
1 Dustless stripper
2 Vacuum stripper
3 Continuous stripper
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Dustless stripper is used exactly like plain stripper except that the fan is
connected to the suction fan
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
A carriage which supports two suction nozzles(one for cylinder
amp the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
This is a nozzle and suction type of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the mc for
being worked again
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Objects
As a card operates the action of fibres and dirt with it gradually wear
the points of wire causing them to become poor cleaning point
The purpose of card grinding is to maintain the card clothing in a sharp
condition
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
It is a steel shaft about 7 inch in dia and 42 to 47 inch long The roll is
carried on a shaft about 1 125 in dia The grinder roll is entirely
covered with emery fillet
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
bull It consists of a narrow roll 35rsquorsquo wide amp 7rsquorsquo in dia Mounted on a hollow
steel shell of 46rsquorsquo or 51rsquorsquo long suitable for 40rsquorsquo or 45rsquorsquo wide cards
bull A long traverse from one end to the other end of the card is given
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
A roller similar to the stripping roller but having long coarse widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week and when every grinding is done
This removes the rough barbs as well as cleans out the embedded dust
fine seed and leaf particles
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibres remain comparatively in bigger
size
Fibres remain comparatively in small
size
2 Additional costs in terms of scutcher
operation lap transportation card
stoppages and lap wastages
Less additional costs required as
compared to lap feeding
3 From productivity point of view LF
carding is not advantageous than of CF
From productivity point of view CF
carding is advantageous than that of LF
4 Variation in feed the material may be
there
A mechanism to feed the material at
uniform weight per unit length amp width
5 Stoppage due to lap changes Direct automatic feed to card increases
BR working efficiency
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Sr
No
Conventional method of feeding
material to card
Modern method of feeding material to
card
6 Extra labour f or lap transportation Elimination of Man power required
during scutcher operation
7 Compression of fibres in the lap poses
problem during opening in carding
No problem during opening in carding
8 More wastes due to lap tail amp damages Processing of rejected lap is avoided
9 Irregularity of sliver weight due to
improper unwinding of laps
Elimination of irregularities due to
double laps lap splitting lap piecing
10 Reduction of 1 CV in chute feed
carding system
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Fig Setting positions on the card
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
AManufacturer Rieter Truumltzschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [empty] 180180253 3 x 1725 1 x 350
Licker-in rpm 935 - 2 306 930 - 2 700 640 - 1 640
Main cylinder [empty] 814 mm 1 287 mm 1 290 mm
Main cylinder rpm 600 - 900 300 - 560 up to 650
Integrated grinding IGS-classic No by hand only No by hand only
Doffer [empty] 680 mm 700 mm 706 mm
Delivery [mmin]
300 400
mechanically 400 500 with IDF up to 400
Flat bars 79 84 75
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
In working position 27 30 25
Flat direction backward backward backward
Power required for
75 kgh 15 KWh 18 KWh -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max
draft of 5
IDF (leveled) max
draft of 3
max 800 mmin
delivery
max 500 mmin
delivery
RSB (leveled) max
draft of 5
IDF-R (rectangular
can) max draft of 3
max 700 mmin
delivery
max 500 mmin
delivery
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U of sliver
Bulky sliver
Higher breaks
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Patchy web
May be due to loading on the cylinder damaged or pressed wire
points waste accumulation below cylinder under casing or defective
under casing
Singles
May be due to lap licking less feed in chutes part of carded web
getting sucked by the waste extractor damaged doffer wire and direct air
currents hitting the web
Sagging web
May be due to insufficient tension draft very high humidity
worn out key in the calendar roller gears heavy material fed to card and
inadequate calendar roller pressure
High card waste
High card wastes are due to damaged under casings higher flat
speed wider front plate setting closer setting of flats and higher
pressure in suction unit and fibres getting ruptured
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Low nep-removal efficiency
Blunt wire points too wide setting between feed plate and licker-in
uneven settings burrs in front plate back plate and card wires of coarse type are
the main reasons for low nep-removal efficiency
Higher U of sliver
Worn out parts eccentric movement in coiler calendar or table calendar
rollers uneven feed waste accumulation in material patch improper settings and
loading of fibres on cylinder and flats are some of the reasons for higher U of
card sliver
Bulky sliver
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure
Higher breaks
Very small trumpet worn out trumpet uneven sliver with bunches of
fibres worn out gears damaged clothing air currents disturbing the web improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Objectives
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Objectives
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats
To remove impurities like motes sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible both transversely and longitudinally on the
cylinder surface
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Major developments takes place wrt
1] Improve the opening of tuft at high rate of feed in high
production cards
2] Distribute the tuft as evenly as possible on the cylinder
3] Extract max trash with minimum loss of spinnable fibres
To achieve first objective
- Licker-in speed is increased in the range of 1150-1800 rpm
- Introduced 23 licker-in for gradual opening of tuft eg Ms
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920 1350 and 1800 rpm respectively
Fig Shows 3-licker-in
arrangement
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
To achieve second objective
- Ms Marzoli has introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300
- Ms Nagoya introduced card analyzer or uniopener
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
To achieve third objective
- mote knives placed in the reverse or inverted
- Ms Mafatlal Engineering introduced comb bar and waste
control knife
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Research done by Shirley institute
The essential changes in the cleaning region are
1 The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate
2 The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card
3 A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in
A - Deflecting plate B - Undercasing
B1 ndash Grid CC1 ndash Making-up piece
B2 - Perforations on the undercasing
D ndash Guard EF ndash Setting plate
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Deflector plate consist of mild steel strips of 316rdquo thick
The operation edge of the plate nearest to the taker-in is beveled at
45deg and is set 18rdquo to 316rdquo from the taker-in
The setting between taker-in grid to the taker-in nearest cylinder
should be frac14rdquo to 516rdquo
The setting between the nose of the taker-in grid and taker-in can be
varied wrt amount of lint rejected
Setting frac14rdquo to frac12rdquo - more lint rejected
Shorter the grid more lint is rejected
For short staple cotton - 8rdquo grid
For medium staple cotton - 7rdquo grid
For long staple cotton - 6rdquo grid
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
- Ms CrosRol Ltd
Introduced fiber retriever
- Modification in under
screen region
- 1 waste reduced
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Questions
Enlist the modernasation in licker-in
Explain working of fiber retriever
Explain Shirley modification
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Questions
1 Enlist licker-in region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist licker-in region developments in Crosrol Mark-4 High
production card
3 Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist licker-in region developments in Rieters C-4 High production
card
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Objectives
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Developments in carding zone cylinder zone takes place wrt
- Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing amp even distribution of tuft on cylinder
- Improve carding effect of the flats to match with heavy feed
- Improve parallelisation and removal of further impurities before
the transfer of fibers to the doffer
- reduce the waste
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
1] Improvement in cylinder construction
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing
All cylinders are provided with ball-bearings and dynamically
balanced
In Ingolstandt card cylinder width increase upto 15 times to cope up
thick feed
In Cros Rolverga MK4 card cylinder dia Reduced by 20 to add
stability and strength
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
2] Development in cylinder back zone
Development wrt increase the life of flat tops and prepere the tuft
for better carding at flat zone
The system offered by Viking Viking 200 and Viking 400
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment
Unique Features
- The segment are made up of precision punched teeth sheet
which are hardened polished and assembled into carding segment of
around 40rdquo long and 32mm width
- The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder thus offering maximum carding surface
Viking 200 pre-carding segment
width 64mm teeth density 60 pointssqinch
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
3] Developments in cylinder flat zone
Development wrt
i] increase the effectiveness of flats
ii] reduce flat waste
Wrt first objective
In SACM card running the flats in opposite direction
Adv - clean flats at delivery end of cylinder with more efficient
carding and cleaning
- Choking due to waste avoided
Wrt second objective
- Stationery carding surface in place of flats for reducing flat
waste
- But it will more applicable for processing synthetic fiber
- Ms John Hollingsworth develop card master of stationery flats
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Consist of four strong stationery aluminum plates with metallic
clothing
Providing greater surface than revolving flats
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia
Advantages
- Weight of card reduced by 320 Kg
- Reduced maintenance due to lock of moving parts
- No flat waste
- Provide max carding area
- Improves carding quality
- Long life since they can be ground
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
4] Developments in cylinder front zone
Objectives i] to improve the parallelization of fiber
ii] to extract the waste
To achieve first objective Viking 400 post-carding segment developed
- consist of four teeth segment total width of 128mm and teeth
density 150 pointssqinch
- mounted on doffer side of cylinder
To achieve second objective Trash Master TM 2000 developed
Continuehelliphellip
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Questions
Enlist the modernasation in cylinder front zone
Explain working of card master
Enlist the modernasation in cylinder back zone
Which developments takes place in carding cylinder
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Questions
1 Enlist carding region developments in Trutschlerrsquos Exact Card DK-
740 High production card
2 Enlist carding region developments in Crosrol Mark-4 High
production card
3 Enlist carding region developments in Ingolstadt Super Card KV-12
High production card
4 Enlist carding region developments in Rieters C-4 High production
card
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Objectives
To study trash master
To study various attachment in carding
To study control of waste in carding
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Trash Master TM 2000
- Introduced by Ms Hollingsworth
- Removal of vegetable matter trash short fly sticky particles
micro-dust and fused man-made fibers
- A special knife is set to the cylinder wire
- Requires 165msup3 air or 2 millibar low pressure
Advantages
- optimum removal of vegetable matter trash short fly sticky
particles micro-dust and fused man-made fibers
- improve yarn quality due to elimination of impurities
- Reduced cleaning of OE spinning rotor
- Lower card room dust levels
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Doffing Devices
- Improved doffer comb
- Roller doffing device
- Doffing and cleaning devices
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Introduction
Licker-in waste
- Role of air currents
- Modificationattachment to cards
- Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Questions
What are different attachments in the carding
Explain working of trash master
How can you control card waste
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Objectives
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Careful control of sliver uniformity is necessary in the spinning
process to minimize the production of streaky fabrics waste of raw
material and to waste of production time
Limitations of traditional methods of controlling sliver uniformity
Need for Autoleveller
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Advantage of installing autoleveller at card draw frame
They control the thickness of individual slivers
They are followed by greater no of doublings
They are generally cheaper
Classification of autoleveller
1] Mechanical system of control
2] Electronic control
Control systems are classified into
1] Open loop
2] Closed loop
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Open loop
- Variation is corrected in draft zone by varying speed of OP
rollers (on card) or IP rollers (on DF)
- Correction follows measurement so there is no check that
correction was correctly applied
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Closed loop
- Variations corrected in draft zone by varying speed of delivery
rollers
- Correction precedes measurement so system check that
lsquocorrectionrsquo was correctly applied
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Working principle
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types
Long term autoleveller [LTAL]
Short term autoleveller [STAL]
Short term autoleveller and dual
autoleveller
Fig Mechanical Autolevelling System
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
They are classified as follows
Very short variations up to 25cm
Short term variations from 25cm to 25m
Medium term variations from 25m to 250 m
Very long variations more than 250 m
Types
Long term autolevelling UCC-L Model L
Medium term autolevelling USTER-M controller
Short term autolevelling UCC-S
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Limitations
The Uster M- controller is suitable for every bright fiber
Influences of color lustre staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster as is the reflection of card clothing
But when the dark
staple fibers are processed
[eg Heavy blue black] the
Uster M- controller has to
be switched off
Advantages
- Reduction of required test
- Improved carding
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
FigShort term autoleveller
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Questions
What are need of autoleveller
What are the different types of autoleveller
Tell me the principles of autoleveller
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Objectives
To study fibre neps and their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Neps are small entanglements or knots of fibers
In general two types of neps can be distinguished fiber neps and seedcoat
neps that is small knots that consist only of fibers and others containing
foreign particles such as husk seed or leaf fragments
Fiber neps predominate particularly fiber neps having a core mainly of
immature and dead fibers
Neps generated due to Fiber fineness picking hard ginning
Based on Uster Technologies Inc amount of neps per gram in 100 cotton
bales
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Classification of Neps
For cotton fiber there are five types of Neps These are ndash
Process Neps Commonly produced by faulty carding or up to
spinning yarn
Mixed Neps Fibres tangle around a foreign materials For
instance ndash Grit
Immature Neps Generally form by processing immature fibre
Homogeneous Dead Neps A tangle of nearly all dead fibres
Fuzz Neps A fault of short fuzz fibers
Count of Neps
Nep count is the no of neps per 100 square inches of card web
forming ( a standerd hank of sliver of 12 NE on a 40 inch wide card)
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
How To Measure Assessment the Count of Neps
At first a web is collected from the card placed on a 10 inch times 10
inch black board Then the neps are counted and the no of neps found is
corrected fro any difference in hank or card width
Mathematically Nep Count n = m times 100 [ m = no of neps per inch
square card web]
Modern Method of Neps Assessment
With the help of AFIS
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Necessity
- To meet the rigid environmental protection regulations of
advanced countries
- The control and removal of dust also reduces dust generations
on the machines following the cards
- The yarn quality is also improved
- The efficiency of rotor spinning is improved
To achieve this necessity
- Shirley institute develop Shirley pressure point exhaust system
- Improved waste suction system
- Internal suction system
- Under card waste removal system
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Fig Shirley Pressure Point Exhaust System
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Questions
What is neps
How can you asses the neps
Tell me about dust and waste extraction system in carding
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Objectives
To study microprocessor used in carding
Summary of unit
Assignment
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Improved waste suction system
Features
- All the high pressure points must be enclosed
- Provision to segregate upper card waste from under card waste
- Continues removal of dust by a central suction system
- Intermitted blowing system for removal of under card waste
- Dead spots should be eliminated
- Complete enclosure of card
- System to recycle the waste
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Internal Suction system
The integral fan for internal suction creates a vacuum with in the
outer shell Thus no dust from the card escapes into the workroom
The suction is very effective in the removal or fly waste dust and
micro dust which are released during carding
Dust and wastes are removed at all points of occurrence feed
flat entry flat strips web delivery and waste chamber under the card
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card
The exhaust air is conveyed to air conditioning system The
amount of exhaust air is 2300 m3h per card
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Under card waste removal system
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell
The over card wastes including flat strips are collected in the
foremost filter
The intermittently acting central suction system
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Quality Assurance MIS
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Summary
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
Questions
What is MIS
What improvements are made in carding suction system
What improvements are made in waste suction system
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
1 Enlist modern developments in Trutschlerrsquos Exact Card DK-740
High production card
2 Enlist modern developments in Crosrol Mark-4 High production
card
3 Enlist modern developments in Ingolstadt Super Card KV-12 High
production card
4 Enlist modern developments in Rieters C-4 High production card
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
1 Explain necessity amp objects of carding mc
2 Explain construction amp working of carding mc
3 Elaborate on flat actions and carding force
4 Elaborate on types of card clothing
5 What are the objects of taker-in region Explain with diagram
6 What are the objects of carding region Explain with diagram
7 Explain stripping grinding and burnishing operations
8 Explain various settings of carding amp its effect on yarn quality
9 What are the factors affecting fibre transfer at card Explain
10 Explain causes for Carding faults and its remedies
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt
1 What is autolevelling
2 Explain different types of autoleveller with their advantages and
disadvantages
3 How the card waste is control
4 Explain the modern developments in card
5 The surface speed of coiler calender is calculated and found to be 40
mtsmin If the linear density of the sliver is 42 ktex (42 kgkm)
what is the production of carding mc per 8 hr shift at 85
efficiency
6 Calculate the production of Carding mc in kgs8hr shift at 90
efficiency
Given data delivery roller speed= 250 rpm CCR dia = 2rsquorsquo
Hank of material = 0012 gmt