Optimisation of drawframe autoleveller

Hitesh Choudhary
www.facebook.com/hitesh.choudhary1

Objects of drawframe

Drafting

Dust removal

Equalising

Parallelising

Blending

What is autoleveller?

It is a online monitering device in spinning process. It has become an integral part of the spinning process for production of high quality yarn. It helps in achieving consistent count cv%.

Need of autoleveller

To survive in this age of high competition, it has become necessary to produce an internationally accepted standard yarn quality. Carded slivers fed to drawframe to drawframe have high degree of uneveness that cannot be tolerated. Comber contains infamous piecings. Higher CV% affects the appearence of dyed fabrics by absorbing the dye unevenly.

Norms for CV% at different stages

Material Wrapping length (yards) Without autoleveller With autoleveller

Yarn
Roving Drawframe Sliver

120
15 5

2.5 3
1.5 1.8 0.7 0.8

1.5 - 2
0.9 1.2 0.4 0.5

Drawframe Sliver

1.5 1.6

0.9 1.1

Object of autoleveller

To maintain consistent hank of sliver. Principle: Adjust the Draft continuosly, which will depend on thickness of material fed.

Types of autoleveller
Open Loop Closed loop

Types of autoleveller
Open Loop
This system is effective for short, medium and to some extent long term variations Lack of self monitering More popularly used

Closed Loop
This system is effective for long term variations
Selfmonitering

Rarely used

Servo Drives
Trtzschler HSR 1000

Various parts of autoleveller

Scanning roller Signal convertor Levelling processor Servo drive Quality monitor sensor

Important parameters for quality levelling

Levelling intensity Levelling action point

Levelling Intensity

It indicates the amount of correction to be done. It is to decide the amount of draft change required to correct feed variation. The correlation between mass and volume for different fibres is not same.

Levelling action point

The calculated correction should be done on the corresponding defective place. The time required for the defective material to reach the correction point should be known. Levelling action point depends on break draft, main draft roller setting and delivery speed

A% test
Sliver weight in ktex (n-1) slivers 1 2 mean A%
Over-compensation: For (n-1) slivers

n slivers

(n+1) slivers

Reduce levelling intensity by A% For (n+1) slivers A% = (ktex(n-1) ktex(n) X 100 levelling intensity by A% ktex(n) X 100 A% = (ktex(n+1) Under-compensation: Increase ktex(n) ktex(n) Drawframes maintained in good conditions achieve deviation between 0 and 0.5 or between -0.5 and 0 A% + : over-compensation A% + : under-compensation A% - : under-compensation A% - : over-compensation

Quick test for levelling action point

a)

b)
c)

Levelling action is OK. Levelling action is too late Levelling action is too early

Quick test for levelling intensity

a) b)

c)

Ideal diagram. Under compensation, increase levelling amplification by A% Under compensation, increase levelling amplification by A%

Calibration
Need of calibration: Calibration is required because even the best instruments drift and loose their ability to give accurate measurements. On autolleveller callibration is done for Scanning rollers Pressure on scanning rollers Servo motor

Calibration for scanning rollers

For rieter RSB-D30 scanning roller calibration is as follows
Scanning roller current levelling Distance guage 3mm 4mm 5mm 6mm Value 3.3 V 5V 6.7 V 8.4 V

Pressure on scanning rollers

Material Smooth, elastic fibres, Combed cotton Cotton carded High crimp and bulky fibres, such as acrlyic, polyester (W-type) Extremely high bulk, and micro fibres Polypropylene Scanning roller pressure in KG 100 120 130 140 160

Calibration for Servo motor

Trim potentiometer Tacho is adjusted in such a way that actual value equals target value.

1)

Calibration servo drive -25% deviation > yes target 1487 actual 1486
Calibration servo drive +25% deviation > yes target 892 actual 890

2)

Laser based autoleveller

Laser beam is used for measuring the sliver thickness.

LDR is used for sensing the intensity of laser beam.

Fast in response, No fibre rupture, no mechanical parts High cost

Advantages of autoleveller

All variations are corrected. Count CV% will be consistent. Thin places in sliver and hence in the yarn will be low. Higher efficiency in further processes.

Conclusions

For obtaining good yarn quality, installation of autoleveller is a must. As long as the autolevelling system is set properly, advantages mentioned above can be achieved. Otherwise, the negative impact will be very big compared to working without autoleveller

References

RSB D-30 & RSB D-45 manual A project on Assesment of autoleveller on breaker and finisher drawframe under guidance of Prof. S.D. Mahajan & Prof. M.S. Kulkarni A practical guide to Combing and Drawing W. Klien www.textilespinning.blogspot.com Trtzschler HSR 1000 brochure Technological study of autoleveller at drawframe on cotton yarn quality nasir mahmood, journal of applied sciences, vol 6, year 2006, pages 287-291 Studies on autoleveller in drawframes M.S.Indradoraiswamy, P.Chellamani, SITRA, 34th Joint technological conference page 1319