ENERGY CONSUMED IN PNEUMATICALLY LOADED DRAFTING OF A RING SPINNING FRAME WITH P3-1 TOP LOADING ARM

A Study on the power consumed in the drafting apparatus of a Ring Spinning Frame using pneumatic arm loading.

 

Prepared by J Venkatasubramanian, Research Engineer, Apex Precitech., Coimbatore

The objective is to find the load consumed for excess/ deficit loading of the bottom rollers by the loading arm of a pneumatically loaded drafting system. Another objective is to calculate the actual cost of such an increase for a mill.

The Rieter/ Lakshmi Rieter type of drafting with their current P 3-1 top arm is taken for analysis. Assumed is that one complete ring frame has 1008 spindles and the mill has 25,000 spindles.

The standard motor capacity is 45 KW and the percentage load consumed in the drafting is taken as 25 % i.e., 11.25 KW.

It is known from studies on P 3-1 top arms that the loading pattern from front to back roller of the drafting is as follows

Front- 16 kg       Middle- 12 Kg     Back 16 Kg.

For an optimum performance in cotton spinning conditions technicians keep these values. Also, at the recommended air pressure of 1.6 bar, only these values are recorded using Apex Top Arm Load Gauges. We can take a total load of 44 Kg for one top arm.

Caluculation:

Total number of top arms – 504

Load per arm – 44 Kg

Total drafting Load – 44 X 504 =  22,176 Kg

Power consumed for one full machine = 11,000 watts

(11,000 watts are consumed by an exertion of 22,176 Kg.)

Therefore , for one Kg , the load consumed is   = 11,250 / 22,176 = 0.507 watts

The P 3-1 top arm is centrally pneumatically loaded and the increase of air pressure fed into the machine will result in the increase of top arm loads in all the top arms. Another feature in the P3-1 top arm is that the increase of one kilogram of the front roller in the standard pin setting of the P3-1 top arm will result increase in other rollers too. The ratio (front: middle: back ) is 1 : 0.5 : 1

Hence, if we assume the front roller is loaded in excess of 1 kg (over the normal of 16 Kg) the loading pattern will be like 17 :12.5 : 17. The increase in load will be 2.5 Kg total. For 504 top arms the excess load applied  = 2.5X 504 = 1,260.00 Kilograms.

Since   we arrived at the power consumed per kilo as 0.496 watts, the total power for 1,260 Kilos of excess loading will be

= 1,260 X 0.507 = 638.82 watts.

For 24 hour running of the machine, the power consumed will be = 24 x 638.82

= 15,331.68 watts= 15.33 KW

Converting into energy units the 24 running consumes 15.33  kilowatt hour (units)

Calculating for 25000 spindles (25 machines)  the excess energy consumed per day  will work out to be            = 25 x 15.33 = 383.25 units

For 365 days the calculation will be = 1,39,886.25 units

Considering Rs 7.00 as an average cost of a unit as in Tamil Nadu the Rupee equivalent of the excess energy consumed is                                             = 1,30,886.25 x 7

=  9,79,203.75 Rupees per annum.

 

Since this cost is for unit increase of load , i.e., by 1 kilogram, for any further increase , the cost can be got by multiplying by the factor. For example , for 1.5 kilogram increase, the cost can be simply  1.5 multiplied by 9,79,203.75.

This can be used as an empirical method to calculate the costs for any increase or decrease of air pressure.

Lakshmi Rieter P 3-1 Top Arm Loading Details

The Rieter P 3-1 is easily the largest populated spinning top arm in the world today. I had already written about this top arm in a separate post. see the article <here>

This is a pneumatically loaded top arm with the benefit that even upon regrinding of the top roller, the load applied remains the same. The load is transmitted to the top arm via a fulcrum loading point.

From the arm the load is individually transmitted via an arrangement of loading pins. This is simply placement of the pivot positions of the front and middle rollers in one set and the back roller alone as another set. The pin positions can be in three positions and the position will decide the intensity of load in that region.

For example, if the pin is inserted in the last pair of holes, the loading will be more on the back roller than the front.

The figure will explain the construction. The points ‘m’ and ‘n ‘ determine the load sharing ratio between the front middle and back rollers.

The top arm load of P 3- 1 is front 16  Kg, middle- 12 Kg, back- 16 Kg. The hexagonal arm bar houses a lengthy hose which exert load on the top arm on a bent lever. The advantages are that even after regrinding of the rubber roller (cots) the top arm load does not diminish.  This is due to  the fact that the area of the hose and the pressure remain constant and as a result, the load is also constant.

Despite its many advantages, the top arm is found to give erratic load readings because of following reasons.

1. Weakening of the hose material.

2. Leakage in the air line/ hose

3. Play developing in the key joints where load is transmitted.

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SUESSEN ELITE COMPACT SPINNING AND TOP ARM LOAD SETTING

Textile technicians the world over are aware of the original contributions that the name ‘Suessen’ brought into the Industry. They were the originators of the first plate spring loaded top arm with individual load adjustments.

A decade back, Suessen again pleasantly surprised everyone with their “Elite Compact spinning system”. The technology was revolutionary. With the help of a driving  front roller running over an oval tube, a compacting zone was created. In this zone, a porous apron in fact runs between the runner and the tube. The tube is connected to vacuum and this vacuum is applied to the travelling fibres in the form of a calculated slot. The fibres are aligned on a central axis by the action of the vacuum and this compacted strand is then gripped by the roller and twisted and spun in the same manner using the ring and traveller thereafter.

Millions of spindles are now retrofitted with Elite Compact system and they continue to produce excellent standard of compact yarn.

Well, we at Apex saw a great opportunity for us in Elite compacting systems. We knew that drafting load setting in such systems are an absolute must. Further, a fourth roller meant that it shared (or took away) some of the load of the second roller. Hence, the second roller load has to be increased to avoid undrafted fibres. Instead of the usual 14 Kg for the second roller, 18 Kg gave excellent results with some clients.

The clients continue to use the gauge at every regrinding of the rubber cots since loads may vary then. More and more spinners around the world are buying and using the gauges to have a first hand knowledge of what is going on in the compact spinning draftings.

Some clients have argued that they have seen no immediate benefits arising out of using the Apex Top Arm Load Gauge. We pointed out that these machines were new . Just after a year, the same customers have told us that the Top Arm Load Gauge is an indispensable tool in their mill. They have also confided that this gauge is more helpful in diagnosis of the drafting since ruling out problems in drafting loads helps them to analyze other areas.

To read more about our gauge click the following link

<<Apex Top Arm Load Gauge>>

If you liked this article, and would like to leave a comment click <here>

J Venkatasubramanian

RoCoS Compact spinning and Apex Drafting load gauges

RoCoS was launched  by Rotorcraft AG amidst great expectations. Till then compact spinning was conceivable by pneumatic suction only. It was upto RoCoS to demonstrate a neat, decisive mechanical set up to compact the spun yarn. This means an enormous power saving over conventional pneumatic suction type condensing mechanisms.

RoCoS is an ingenious development over the conventional drafting for spinning. By adding an extra roller running at the same speed as the front top roller, a new passage area for the yarn fibres is set up. These fibres pass through a mechanical guide like condenser made of ceramic material. This condenses the fibres which are then clamped by the newly introduced front roller and twisted by usual means by the ring + traveller mechanism.

(pictures from the official website of M/s Rotorcraft AG)

RoCoS and Importance of Top Arm Loads:

Since, the newly created roller shares the same saddle as the second roller, correct load setting of these two rollers are of utmost importance. Almost every spinner who has installed RoCoS in his mill has seen benefit from regular load setting.

RoCoS is installed in both SKF PK 225, (also pk 2025), and P3-1 draftings. In all of these draftings, correct load setting is important. The front saddle load has to be increased so as to compensate for the load sharing with the front idler roller.

Apex has been at the forefront in drafting load measurement and is a proud supplier of many Top Arm Load Gauges to Rotorcraft over the past six years.

To see a write up on our Apex Top Arm Load Gauge , click on this below link

Apex Top Arm Load Gauge

If you liked this article, please leave a comment by clicking on this <link>

Venkatasubramanian

SUESSEN HP-A 310/320 /3010 AND DRAFTING LOAD ADJUSTMENT WITH APEX

The textile machinery major Suessen, has continuously introduced breakthrough design features in Ring spinning and Roving top arms. Suessen was the first to introduce the plate spring for loading the arms.

Its vintage UT 200 and UT 600 series of  top arms have proved beyond doubt that plate springs are by no means inferior to helical compression springs (as promoted by SKF) .  Suessen’s technological uniqueness further improved with the HP-A 310/320 top arms finally culminating in the spectacular ” Suessen ELITE” compact spinning system.

The HP-A top arm is a rigid top arm for ring spinning. The front roller is loaded at 16 Kg which is  shiftable to 12 Kg by turning a nut.  The middle apron roller and the rear roller are loaded at 14 Kg each.

When retrofitted with Elite compact spinning system, the front roller is set at 23 Kg and shiftable to 17 Kg.

Apex has always been a favourite with spinners when it came to top arm load measurement. Suessen top arms are no exception. We were approved by Suessen and their Indian counterparts are insisting on checking with Apex Top Arm Load Gauges in all their installations.

To view the full article on our Apex Top Arm Load Gauge please click on this <link>

If you find the above article useful and would like to comment on it, please click this <link>

Venkatasubramanian

RIETER P3-1 TOP ARM AND DRAFTING LOAD MEASUREMENT WITH APEX

Rieter P3-1 is perhaps the most widely distributed top arm in the spinning industry today. It is a simple top arm to work with but a little complex to understand in its intricacies.

This top arm is supplied by both Lakshmi Machine Works Ltd and Rieter Textile Systems in their Ring Frames. Rieter considers this top arm so effective that the same arm is used in Rieter’s flagship ” ComforSpin” compact spinning frames with slight modifications.

This top arm is pneumatically loaded. A long hose runs through the hollow hexagonal arm bar that also doubles as a housing for this pressure hose. This hose is pressurized to around 1.4 to 1.8 bar to get desired loads at the rollers.

The top arm is loaded from the fulcrum. The fulcrum is loaded by the expanding hose inside the arm bar. When the arm engages with this fulcrum, the load is transmitted to the arm area.

In this area, there is a bridge which divides the applied load to the combines front and second rollers and to the third rollers. The division of load is varied by shifting the pivoting distance of division by simply altering the position of a locating pin. This is an ingenious setup whereby simply by changing the position of the pin, loading ratio is changed.

The load transmitted to the first and second roller is through another bridge which again splits the load between the fron and second (apron) rollers, Here again three pin positions are given by which the ratio of loading between them can be changed.

The recommended load setting values for cotton spinning in the P3-1 top arm is like this

As always, Apex Top Arm Load Gauges were the first   to measure the top arm loads in P3-1 successfully and accurately from the very beginning.  We were initially discouraged by the spinners in the measurement of P 3-1 saying this was a pneumatic system and measurement was not at all necessary even after cots regrinding.

But experience is a better teacher. When we demonstrated the possible variations with worker neglect, pneumatic hose wear, and top arm general wear, spinners quickly understood its value. One defective top arm can play as a black sheep and spoil the quality of a lot. Variations of even 5 to 10 % in top arm loads can alter CSP and USTER values. Yarn appearance is directly affected by variations in top arm loads.

Also one idle top arm is a potential loss to  the mill. The gauge may be small but its indispensability to a spinning mill is undisputed. Now, mills are buying these gauges right at the project stage.

You can read more about our Apex Top Arm Load Gauge (with video  demonstration) by clicking on this <link>

If you have found this article useful and would like to comment on it , please click on this <link>

J Venkatasubramanian

TRUTZSCHLER TD O3 DRAW FRAME AND APEX DRAW FRAME LOAD GAUGE

Trutzschler draw frames have always fascinated everyone with their original features. Everytime they announced a model, a novel idea would definitely be in there.

click on photo to enlarge

TD 03 is no exception. Built over the earlier HSR series platform, these machines display one extraordinary, never before tried feature. The loading arm is laterally positioned in them instead of the right over top design of the loading arm. In other words, the top arm is designed like a hinged door. Look at the following picture

click on photo to enlarge

This is a four over three roller drafting. The first roll is a guide roll for the web coming out of the drafting and usually is loaded at 15 kgs/end. This roller is seen in the picture with an inclined angle of loading in the front. The remaining three rollers are loaded at 30 Kg/end. The loading is pneumatic and the load is separate for each roller.  This means there is separate air supply to load each roller and each is individually variable.

Apex Draw Frame Load Gauges are eminently suited for measuring the loads in TD 03 machines. In fact, we have come out with a special gauge for TD 03 in view of its restrictions in the drafting space.

Look at the article for a description of Apex Draw Frame Load Gauge by clicking on this <link>

If you liked the above article and find it useful, you can leave a  comment by clicking on this <link>

J Venkatasubramanian

RSB and SB Draw Frames and Drafting Load measurement with Apex Gauges

Rieter launched their famous RSB draw frames about fifteen years back which still remains the main workhorse in many spinning preparatory departments. The testimony to its success is that the same model is still in production (Lakshmi LRSB 851) in India.  Rieter models still retain  the core design intact.

Lakshmi has this machine in single delivery design. Rieter has the double delivery model SB 20 (formerly SB 2). The drafting system in all these machine are same. The main features of the drafting setup 9with respect to loading)  are

1. Flat bed drafting

2. Three over three drafting.

3. Spring loaded top rollers.

4. Short top rollers to reduce bending of rollers and for even distribution of nipping load to the bottom roller (and the sliver)

5. All the rollers are equally loaded. (32.5 Kg each at ends in all rollers)

6. Adjustment of rollers are possible for all the rollers of one end by moving the locking hook of the loading arms up and down.

7. Each loading cell of the top roller has a spring housed in a casing with fixed loading. (with no provisions for adjustment)

8. Adjustment of loads and equalization are extremely important. Variations of even 1.5 Kg have shown Uster variations. Similarly difference in end  to end loads affect CV % and  Uster .

click to enlarge photos

Apex Draw Frame Load Gauges and RSB Drafting

Spinners across the world are aware of the critical importance of regulation of Drafting Loads of RSB and SB draw frames. From its very introduction, our Apex Draw Frame Load Gauges accurately measured loads in these rollers and till date most of the modern units of the world are using these gauges.

Please click on the following link to read more on this gauge and to see a video demonstration

Apex Draw Frame Load Gauge

If you liked this article or found it useful, you can leave a comment by clicking on this < link>

Venkatasubramanian

TEXPARTS PK 1500 TOP ARM AND LOAD ADJUSTMENT

Texparts has another trusted speed frame drafting top arm PK 1500 which has found wide acceptance with cotton and synthetic spinners.

This is a spring loading top arm much like its predecessor SKF 1600-40 top arm. This top arm is available in 4 roller and 3 roller versions.

The four Roller version is here

The load setting values for this top arm is here

Similarly the 3 roller drafting is below

And the load setting values for 3 Roller drafting is here below

Conversion: 1 daN(Deca Newton) = 1 Kg

The above loads are variable in steps only by shifting the loading nuts by a special lever. Apart from these , the cumulative load can be increased or decreased by the two setting screws provided at the back of the top arm.

Needless to say, our Apex Top Arm Load Gauges were very successfully used to measure the top arm loads in PK 1500 top arms. Very accurate and reliable, these gauges are the favourite of many a quality conscious spinner. Click on the following link to read on our Apex Top Arm Load Gauge with a video demonstration.

Apex Top Arm Load Gauges

If you liked this article or found it useful you can leave a comment by clicking on this <link>

Venkatasubramanian

TEXPARTS PK 5025 TOP ARM AND APEX TOP ARM LOAD GAUGE

Texparts PK 5025 top arm is a trend setting one in that it carries new design features hitherto unknown in textile drafting.

First, the old concept of individual loading is dispensed with. Second , a pneumatic spring has been employed for load generation.  One may argue that the same principle was used by RIETER in their FS 160 and the later P3 drafting series.

The difference between them is that Rieter design loads the arm near the pivoting point. But in Texparts, the pneumatic spring (a pressurised hose) actually runs through the length of the top arm loading each saddle . This is a fresh outlook at top arm design and going by the customer review and the work it is doing in the spinning floor, the design seems validated and a viable and trouble free one.

They are available in two models. A four roller drafting and a three roller one.

click to enlarge photos

The load setting values are given below.

3 Roller Version & 4 Roller Version

Apex top Arm Load Gauges are the most trusted ones for a keen eyed spinner who wants to keep a close watch over the loads and general behaviour of drafting apparatus. Our gauges are easy to use , easy to understand and trouble free. Their strict calibration checks at our factory ensure that each one measures the exact load every time.

Just check the Product at this link below

Apex Top Arm Load Gauges

If you liked this article or found it useful, you can leave a comment by clicking on this <link>

Venkatasubramanian