Card Sliver Research Articles

Back-propagation ANN to Predict Cleanliness and Quality of Cotton Spinning Preparatory Output: A Comprehensive Research

Background: Modern spinning preparatory has undergone drastic technological changes, but still, individual’s expertise-based decisions govern the complex and non-linear multivariant relationships prevailing amongst raw material (cotton) variables, machine variables, process variables (waste), and product (card sliver) quality. The scientifically precise prediction regarding the cleanliness and quality of card sliver and waste control for the given inputted cotton variables processed on the state-of-the-art machinery setup without waiting for the production and testing of card sliver is still impossible. Methods: The present work describes the use of Aritificial Neural Networks (ANN) for ruling out these limitations on scientific grounds. A complex system targeted at ANN was developed using the "newff" function on the mill's five-year database. Single-group ANN was initially designed to determine the influence of inherent variations in raw cotton fibre properties and trash content on blow room and card performance. A multi-group approach of ANN was developed at a later stage to define the influence of complex interactions amongst various fibre properties on three main quality measures considered at blow room and carding, viz., i) influence of blow room and card on fibre length properties, ii) fibre damage at blow room or improvement at card, and iii) degree of cleanliness of the output material. Results: Reverse modelling for both groups was also successfully designed to demarcate feed cotton quality and cleanliness requirements for targeted blow room or card cleaning performance. Conclusion: A high level of positive endurance was observed for all ANNs. Multigroup networking has proven to be more precise than single group networking.

Study of hooked fiber in cotton yarn based on tracer fiber method

PurposeThrough the tracer fiber method, we strive to more accurately obtain the hook degree, straightening degree, percentage and other characteristic indexes. In order to intuitively represent the hook state from sliver to yarn, and feed back production information in combination with quality test.Design/methodology/approachTaking the cotton fiber as an example, the hooked fibers were studied by using the tracer fiber method. Tracer fibers were made from cotton-type viscose fibers. Tracer fibers and combed cotton fibers were uniformly mixed for many times and used to produce the card sliver, semi-drawn sliver, drawn sliver, roving and yarn. With the help of ZF-20D ultraviolet analyzer, geometric parameters of hooked fibers were measured, and characterization indexes were calculated. And hook indexes and quality indexes were compared.FindingsBy redefining and reclassifying hooked fibers, the change of hooked fibers in the process was tracked and characterized carefully. Some hooks in card sliver are straightened but not eliminated, and will form longer zero-angled hooks in the subsequent process. The straightening degree and number of zero-angled hooks affect the evenness CV mainly.Originality/valueThe characterization of hooked fibers is important for reducing hooked fibers and spinning high quality yarns. There is no uniform standard for the characterization of hooked fibers at present. Most studies are about relationship between process and hook in carding and drawing. There is no research on hooked fibers in the whole spinning process. In the paper, hooked fibers were redefined and reclassified, the change of hooked fibers in the process was tracked and characterized carefully.

The influence of increasing the productivity of the carding machine on the quality indicators of the card sliver

The paper investigated the influence of the rotation frequency of the take-up, main and doffing drums of the C60 carding machine from RIETER on the quality indicators of the card sliver. The raw material used was medium-fiber cotton with a fiber length of 26.5-28 mm. The experimental study was carried out with changing speed modes: rotation frequency of the main drum from 451 to 520 rpm, of the take-up drum from 1018 to 1400 rpm, of the doffing drum from 62 up to 72 rpm.The quality indicators of the produced card sliver were determined using an USTERTESTER-5 laboratory equipment. It was established that an increase in the speed mode of the main working bodies within the studied limits on carding machines does not cause a deterioration in the combing quality.

Features of cotton and viscose vortex yarns directly spun from card slivers

In this study, the possibility of manufacturing vortex yarns directly from card slivers having two different sliver counts is investigated. The fiber type, card sliver count, and yarn count are considered as the selected parameters to be examined due to their effects on unevenness, yarn imperfections, hairiness, breaking strength, and elongation properties. For this purpose, cotton and viscose yarns in three yarn counts, 14.77, 19.69, and 29.53 tex, were produced from two card sliver counts (3.58 and 4.92 ktex) by a Murata Vortex Spinning (MVS) system. The study revealed that vortex yarns can be produced by feeding directly card slivers to the MVS system, and resulting yarns have features compatible with those yarns produced on a conventional production line. In the context of this study, where the drafting process is eliminated, it is recommended to produce yarns from fine card slivers to reach a lower CVm% and imperfection value and to produce yarns by coarser card slivers to reach lower hairiness and higher Rkm values.

THE EFFECT OF SLIVER DELIVERY SPEED ON THE UNEVENNES OF CARDED AND COMBED COTTON YARNS

The purpose of this study is to determine the effect of five different sliver delivery speeds on the yarn unevenness CVm (%). For this purpose, 100% cotton raw material was used, and card sliver samples were produced at five different card sliver delivery speeds (60 m/min, 120 m/min, 180 m/min, 240 m/min and 300 m/min). A total of 600 sample cops were produced in the ring spinning machine, each of which is 10 pieces of knitting and weaving yarn types in the carded and combed machine line, with the yarn counts Ne 20/1, Ne 30/1 and Ne 40/1 from these reed strips produced. The quality characteristics of the raw material used and the produced carded sliver samples were measured using the Uster HVI 1000 and Uster AFIS test equipment. The quality characteristics of the ring yarn cops samples produced on the ring spinning machine were measured with the help of Uster Tester 4 and Uster Tensojet Test devices. The results were analyzed by inferential and descriptive analysis methods. ANOVA analysis method was used for statistical analysis. According to the research findings, in both carded and combed Ne 40/1 yarn samples, an increase in yarn unevenness was observed with the increase in card sliver exit speed, and this increase created a statistically significant difference. The results revealed that the yarn unevenness is directly proportional to the card sliver exit speed and the increase of the card sliver exit speed causes the production of card sliver samples with higher unevenness values (Cvm (%).

Simulation on the fiber arrangement and distribution in the drafting zone

Roller drafting is an indispensable and fundamental procedure in attenuating the sliver to an adequate linear density during the spinning process. In this study, the drafting dynamic process was reflected in the arrangement containing hooked fibers and straight fibers, and the fiber straightness in the drafting zone in real-time. The drafting process was implemented from the initiation of the sliver head moving into the drafting zone to the achievement of the straightening process for all fibers in the sliver. The developed model demonstrated that the simulated weight distributions of various fibers, including the total fibers, back fibers, front fibers and floating fibers, were more in line with the actual results than the simulative ones based on the previous drafting model with the simulation of the straight fiber arrangement in the sliver. In conclusion, the drafting model with the application of the hooked fiber arrangement was effective and precise in quantizing the drafting process of a sliver with many hooked fibers, such as a cotton card sliver. Moreover, the drafting model can offer the theoretical foundation for setting the drafting parameters from the perspective of the distributions of slow-floating fibers and fast-floating fibers.

Observation of Damage of Cotton Fiber in the Processes of Blowing, Cleaning and Carding

The quality of the produced yarn mainly depends on the properties of the raw material, its preparation for spinning, the condition of the equipment, and the preservation of the natural quality of cotton fiber during processing. The question of the number of defects in cotton fiber and their total content is a very important issue for cotton spinning. The non-standardized number of defects in the raw material reduces the quality indicators and yarn yield, which requires additional technological processes; therefore, on the part of production, the requirements for reducing the share of cotton fiber defects are constantly increasing. During processing in blowing and cleaning units and on carding machines, the cotton fiber is mechanically damaged. To observation the damaged fibers, we used the Congo-Roth red paint according to the method of Ch. Dore. Despite the carding is considered the last stage in the process of cleaning the fibers from impurities and defects in the spinning system, 30% of impurities and fiber defects still remain on the card sliver. Besides, it should be noted the carding machine is also considered an additional occurrence of defects, in particular (neps), which reduce the quality indicators of the card sliver and the finished product.

Analisis tentang Setting Roller Gauge dan Break Draft Tidak Merubah Total Draft pada Mesin Roving Rieter type F10 / 55011- 00425 Tahun Pembuatan 1998

At PT Indiratex Spindo, there are 2 units that produce 100% cotton yarn. For unit 1 produces open end yarn, and for unit 2 produces ring spinning yarn. The production process in unit 2 starts from the raw material, namely cotton in the blowroom process, opening and mixing of the cotton so that the shape of the feathers will be processed in the carding machine to further open cotton fibers, clean dirt and short fibers with long fibers. The result of the card is that the card sliver will then be duplicated and drafted on the draw frame breaker, after which it will be processed and duplicated again in the finisher draw frame. Then the sliver drawing finisher will be drafted, given a twist and rolled in a bobbin on the roving machine. The output of the roving machine will then be processed in the ring spinning machine, the roving will be drafted, twisted so that the yarn will then be rolled into the cop, then put in the winding machine to remove thread imperfections or yarn defects and change the cop roll to cones rolls. After the process is complete, the thread will be packed in the packing section. To produce good quality yarn, it is necessary to plan production, repair and maintenance as well as repair machines properly. Drafting is one one process that is very important and to be hard to the quality of the yarn that will be produced. If the drafting process is not perfect it will affect the unevenness of the material or yarn. One of the problem topics related to drafting on the Rieter type F10 / 55011-00425 roving machine in 1998 is that if the break draft is changed, the total draft will change. This assumption is really true because if the draft is damaged, what will change is the main draft, and the total draft will remain the same. Meanwhile, for the correct setting of the roller gauge so that the roving does not experience a high level of unevenness, if the setting is wide, the draft break must be small. And if the arrangement is eternal then the break draft used must be large. The second arrangement is so that the fiber can be properly drafted and does not experience floating fibers or fiber cracks.

Analisis tentang Setting Roller Gauge dan Break Draft Tidak Merubah Total Draft pada Mesin Roving Rieter type F10 / 55011- 00425 Tahun Pembuatan 1998

At PT Indiratex Spindo, there are 2 units that produce 100% cotton yarn. For unit 1 produces open end yarn, and for unit 2 produces ring spinning yarn. The production process in unit 2 starts from the raw material, namely cotton in the blowroom process, opening and mixing of the cotton so that the shape of the feathers will be processed in the carding machine to further open cotton fibers, clean dirt and short fibers with long fibers. The result of the card is that the card sliver will then be duplicated and drafted on the draw frame breaker, after which it will be processed and duplicated again in the finisher draw frame. Then the sliver drawing finisher will be drafted, given a twist and rolled in a bobbin on the roving machine. The output of the roving machine will then be processed in the ring spinning machine, the roving will be drafted, twisted so that the yarn will then be rolled into the cop, then put in the winding machine to remove thread imperfections or yarn defects and change the cop roll to cones rolls. After the process is complete, the thread will be packed in the packing section. To produce good quality yarn, it is necessary to plan production, repair and maintenance as well as repair machines properly. Drafting is one one process that is very important and to be hard to the quality of the yarn that will be produced. If the drafting process is not perfect it will affect the unevenness of the material or yarn. One of the problem topics related to drafting on the Rieter type F10 / 55011-00425 roving machine in 1998 is that if the break draft is changed, the total draft will change. This assumption is really true because if the draft is damaged, what will change is the main draft, and the total draft will remain the same. Meanwhile, for the correct setting of the roller gauge so that the roving does not experience a high level of unevenness, if the setting is wide, the draft break must be small. And if the arrangement is eternal then the break draft used must be large. The second arrangement is so that the fiber can be properly drafted and does not experience floating fibers or fiber cracks.

Effect of Feed Plate to Taker-in Distance of Carding Machine on the Quality of Cotton Card Sliver and CVC Ring-spun Yarn

Effect of Feed Plate to Taker-in Distance of Carding Machine on the Quality of Cotton Card Sliver and CVC Ring-spun Yarn

Processing of waste carbon and polyamide fibres for high-performance thermoplastic composites: influence of carding parameters on fibre orientation, fibre length and sliver cohesion force

The processing of waste carbon fibre on carding machine for the developments of nonwovens, tapes and hybrid yarn structures is an emerging trend. These structures are widely used to enhance the performance efficiency of recycled carbon fibre reinforced thermoplastic composites. The aim of the research presented in this study is to process waste carbon fibre on a carding machine and to investigate the influence of different carding parameters on waste carbon fibre. For this purpose, card slivers composed of waste carbon and polyamide fibres were developed on a double cylinder card machine by varying technical parameters. Then, effect of these parameters on card sliver quality was assessed in terms of fibre orientation, fibre length and sliver cohesion force. Results revealed that fibre orientation and fibre length is significantly affected by technological parameters carding zones, whereas the sliver cohesion force is significantly affected by the speed of feed roller and doffer.

Research of Relation between Card Sliver Quality and Yarn Quality

To research relation of card sliver quality and yarn quality, influence degree of card sliver parameters on yarn quality was analyzed through gray incidence analyses method and least square method, the concrete formula was got, it is feasible for production to adjust carding processing in time, enhance yarn quality stably.

Effect of Humidity on Nep Movement in Electrostatic Field

In order to study the effect of humidity on nep movement in electrostatic field, a self-made experiment instrument was made. By this instrument, under the several kinds of different humidity, fiber neps and SCNs (seed coat neps) gotten randomly from card sliver or raw cotton were laid on down-pole-plate and then the up-pole-plate voltage was increased gradually. The voltages when the neps leaving the down-pole-plate were recorded. With statistical method, the take-off voltage averages of different kinds of nep under different humidity were calculated. It can be concluded that charging time of neps decreases largely and the take-off voltages of neps also reduce with the increase of air humidity in certain range.

Effect of flat heel-toe difference of a card on nep removal

Effect of flat heel-toe difference (HTD) of a card on neps of card sliver and yarn was studied. The card sliver and yarn were produced under different HTDs, doffer speeds and cylinder speeds. The neps in card sliver and yarn were tested with Premier aQura and yarn evenness tester of PT7000, respectively. Effect significance of HTD on card sliver neps and yarn neps was analysed with SPSS. The results show that HTD has significant influence on both card sliver neps and yarn neps, and 0.42 mm HTD plan is the best in nep removing. The correlation degree between nep numbers of card sliver and yarn was also analysed with SPSS. It is found that nep number in card sliver has a high correlation with that of yarn, and the sequence from high to low is yarn neps (+140%), yarn neps (+200%) and yarn neps (+280%). It is also found that the correlation degree between nep number of card sliver and yarn is higher than that of seed coat neps (SCN) number in card sliver and yarn neps.

Cotton fiber length distribution modality alteration in ginning and mill processing

Mechanical damage in cotton fiber processing both shifts the fiber length distribution and alters its shape. This leads to length distributions with complex shapes, often bimodal, that cannot be classified based on simple summary statistics. In this research, we quantified the distribution departure from unimodality and its alteration from the seed to the card sliver in order to determine where in the cotton process the complex bimodal shape appears, and to identify its potential sources of variability observed at the bale stage. Results presented in this paper indicate that bimodality is a transient state associated with intermediate fiber damage levels starting from the gin stand. The distribution is unimodal or shows a non-significant departure from unimodality at both the low and high damage levels, i.e. seed and card sliver, respectively. Fiber maturity plays a major role in determining the variability of the distribution modality at any processing stages. A mature cotton typically shows an extended intermediate damage state associated with a bimodal distribution, while an immature cotton will reach an advanced damage level from the early stages of mechanical processing, and thus will not exhibit the bimodality that is characteristic of an early/intermediate stage of the fiber breakage process.

Influence of card to flats settings in the improvement of yarn quality

This project work deals with neps and the emphasis is given on minimizing the neps and neps size in carding for achieving good quality of yarn and fabric. The trials were conducted to justify the quality by changing the card settings (cylinder to flats and cylinder to doffer) and the improvements in resultant sliver and yarn were evaluated on AFIS and UT-3 tester. The neps content in yarn and fabric in relation with existing card sliver, which have been channelized up to yarn and knitted fabrics showed better results when compared to existing ones. After taking trials on different settings, it is found that neps and neps size reduced up to a certain extent.

Test Reliability of Impurity Parameters of Uster AFIS

This paper presents test reliablity of Uster AFIS for impurity test by calculating the Reliable Test Time (hereinafter referred to as RTT) and CV% of test results. The CV% value of test results of impurity-related parameters in card sliver obtained in 8 experiments totally with 313 different plans were calculated. By statistical analysis method, the reliable test time of AFIS for some impurity-related parameters was estimated. It is concluded that the impurity result obtained by 10-time tests with AFIS was inaccurate. The reasons for this are that the sample weight is too small, the impurity is unevenly distributed and the impurity in card sliver may have some loss in the manually-sampling process.

Effect of Electrostatic Web-Cleaner on Card Sliver Quality

To find out the effect of the electrostatic web-cleaner installed on the front plate of carding machine on card sliver quality, the sliver produced under different voltages and gauges of electrostatic plate was tested with Uster AFIS. The results show that card sliver quality can be improved when the gauge and voltage are appropriate. When the gauge is 1 mm, parameters of short fiber content, nep content, impurity content are better at a voltage of 1500 V than those of other voltages; when the gauge is 2 mm, a voltage of 500 V or 3500 V is advantageous to improve the comprehensive quality of card sliver (except for impurity content parameter); when the gauge is adjusted to 3 mm, the impurity content is decreased at 1000 V and the nep content is decreased at 2500 V, but the improvement on card sliver quality is not perfect.

Study on Front Web Cleaner Suction Form of Carding Machine

Effect of web cleaner on front plate suction form of carding machine on the quality of card sliver was studied. The card slivers processed by carding machine with web cleaner installed on the front plate using single and double sides suction forms were tested by Premier aQura. The results show that, when the suction volume is between 120~240m3/h, the range of short fiber content in card sliver is 12.03~14.0% in the single side suction and is 15.6~16.8% in the double sides suction; 5% length of fiber in card sliver is between 34.03~34.04mm in the single side suction and is between 33.64~33.83mm in the double sides suction; effective length of fiber in card sliver is from 29.71mm to 29.80mm in the single side suction and is from 29.52mm to 29.55mm in the double sides suction; total neps in card sliver is between 51~55cnt/g in the single side suction and is between 57~59cnt/g in the double sides suction. Thus it can be seen that under the same suction volume, the front web cleaner with single side suction is more beneficial to improving the quality of card sliver, so it is better for the front web cleaner to use single side suction form.

ANALYSIS OF REGULARIZED CARD SLIVER AFTER SHORT-TERMLEVELLING PROCESS

Abstract Doubling of sliver has ceased to be the fundamental operation for reducing the weight irregularity of spinning halfproducts, which are decisive for the quality of yarn. Its role has now been taken over by the general use of autolevellers. After leaving the regulation zone, card sliver, whose weight irregularity is reduced by a short-term autoleveller, undergoes a process of relaxation. This phenomenon takes place only in the case of regulated sliver. Unregulated slivers passing through a leveller operating with constant draft show few relaxing properties. One reason why autolevelled card sliver has such relaxing properties may be the variation of the drafting force caused by the continually changing draft. The performance of the short-term card autoleveller cannot be unequivocally evaluated. The main difficulty lies in the time span between levelling and measurement, during which the sliver undergoes relaxation. How quickly the autolevelled card sliver is fed to the next machine in the yarn manufacturing process is therefore important, because in the intervening time the initial irregularity of the product may undergo uncontrolled changes.