Anant Spinning Mill A Unit of Vardhman

Industries Ltd.

Name:- RAJAT DIXIT

College:- SHRI. VAISHNAV INSTITUTE OF TECHNOLOGY &SCIENCE(S.V.I.T.S)

Training period- 15 June to 15 July

GUIDED BY :- PRAMOD SHARMA SIR AMOD TIWARI SIR UNIT - 3

To Reduce High Repeater Drum On Winding Machine

Unit-03

This project aims to reduce Repeater cycles in winding machines. Auto coner 338(schlafhrost/saurer)(M/C No. 7&8) were giving (high repeater cycles %),so this project aims in reducing high repeater cycles with help of maintenance and electrical department.

Abstract

IntroductionAs we know the winding is very important process considering the final product specification or quality.

• It remove yarns fault like hairiness, neps, slubs, foreign matters.

• It is used to produce package of required density and shape suitable for next stage of processing.

• It improves the quality of yarn

High repeater drum in winding machine can result in reduction of efficiency of machine, it can also lead to generation of greater amount of hard waste and no. of joints in yarn also increases.

Machine no.

Manufacturer Gauge

3,4,9

SAVIO Uster Quantum 3

1,2,5,6

Mura tec Uster Quantum 3

7,8 Schlafhorst Loepfe(TK940F)

Winding section description(UNIT-3) Unit 3 has 9 winding machines of 3 different manufacturers. Unit has 3 savio ,4 muratec and 2 schlafhrost Winding machines.

Machine Specification• Name Autoconer 338 • Manufacturer Schlafhrost/saurer• Year 2003(no. 7),1998(no. 8)• Model RM• M/c type Right Handed• Clearer Loepfe(TK940F)• No of Drums 60• Magazine Creel Capacity 6• Yarn tensioner Rpm 80• Cone Weight 2.5kg

REPEATERS

Any Unsuccessful splice attempt is called repeater, extra cycles or missing %.Factor which Influence Repeater cycles

• Tension Break• Clearer cuts

• Upper end failure

• Splice cuts• Red light

Tension Break

Tension break depends upon following factors

• LOOP GATE:-loop gate touches the bobbin at the time of bobbin change and splicing ,and prevents the formation of loose yarn. If carbon gets deposited on the magnetic coil of loop gate it will not function properly so at this time it is essential to remove carbon from magnetic coil.

Loop gate

TENSION ASSEMBLY:- It has tension cup and tension motor which ,tension cup should rotate forward and tension motor gearing should be proper.

MOTHER BOARD :- It regulates all 3 factors like (loop gate ,tension assembly, yts), if mother board does not function properly ,these 3 factors will also not function properly.

YARN TENSION SENSOR(YTS):-Yarn tension sensor senses tension in the yarn, and sends signal to the mother board to provide adequate amount of tension to the yarn, if it does not function properly it could result in formation of tight or loose package.

YARN TENSION SENSOR

UPPER END FAILURE:-

DEPENDS UPON FOLLOWING FACTORS

• Upper End Failure increases if yarn get trapped in suction arm, so it could reduce efficiency of suction arm.

• It also depends upon setting between suction arm and package.

• Some times shutter in suction arm gets faulty and increases upper end failure

• Many a times yarn gets trapped in winding drum

• Some times yarn gets coiled in side of package and suction arm is unable to catch it.

Other factors that can increase repeater cycles

• Gripper arm jam (if gripper arm is jam repeater will be high even if all parameters show values in range)

• Adapter:- Has coil spring, if there is problem in coiling its rotation will become tight.

• If there is Entangled yarn in end of bobbin and gripper arm is unable to unwind it, so repeater will increase spontaneously.

• Balloon control ring not in position ,if the yarn is not Passing from center of balloon control ring it would increase tension break and hence the repeater.

• Splice Cuts• Splice cuts increase when the splicer is not doing

correct splicing and it will increase repeater cycles.

• Jam in bobbin change motor ,due to jam in bobbin change motor, the rejection of empty bobbin does not take place and full bobbin will fall on empty bobbin and will result in increase in repeater cycles.

• Splice failure:-Some times splicer is unable to do splicing

• Many times worn out part from splicer assembly jams suction arm & results in high upper end failure.

• Gauge voltage can increase clearer cuts and hence the repeaters. if its value exceeds or reduces from standard gauge voltage ,gauge cutting will increase ,and hence the repeaters will increase.

Steps followed for study

Data collection Identification of problem

working on problem (with help of maintenance. & Electrical persons)

Result

STUDY OF MACHINE NO. 7 (AUTOCONER 338) BY SCHLAFHROST

Machine no 7 Repeater drum Drum no upper end faliure Tension Break Clearer cut Splice Cut Red light Repeater Problem Identified

(.1-.2)% (3-4)/100km (0-75)/100km (0-20)% (2-3)% (0-15)%49 1.2 2 93.9 29.8 18.7 100 Splice faliure

Increased 47 4.3 1 74.1 24.3 20.7 81.4 Splice assembly part broken (27,june,2015) 44 1.6 1.3 203.4 12.5 16.8 78.1 yarn entanglement

32 2 2 178.4 14 35 109 gripper arm jam43 4 1.5 44.5 9.8 10.9 70.4 bobbin change motor jam49 1.2 2 71.9 3.7 3.9 15.4

Decreased 47 0.2 5.3 65.5 7.2 2.1 20 (29,june,2015) 44 0.9 2.2 84.2 10.9 3.3 23.7

32 0.6 3.6 76.5 5.9 1.6 1743 3.6 3.7 59.3 2.9 4.6 21.3

Machine no 7 Repeater drum Drum no upper end faliure Tension Break Clearer cut Splice Cut Red light Repeater Problem Identified

(.1-.2)% (3-4)/100km (0-75)/100km (0-20)% (2-3)% (0-15)% Increased 59 3.3 7.2 300 45 30 109.4 Problem in splicer (29 th june,2015) 57 1.4 3.9 315.3 4.4 22 130.4 Gauge voltage problem

56 3.8 66.8 75.2 27 100 187 loop gate

Decreased 59 1.2 4.9 51.1 10 4.8 19.1 (30 june,2015) 57 0 5.9 70.3 16.24 1.5 21.3 56 0.5 2.9 43.9 6.5 1.6 20.4

27-Jun 29-Jun 30-Jun0

5

10

15

20

25

30

35 32.33

28.3626.11

Reduction in average repeater % cycles after mantainance(m/c no 7)

Date

Repe

ater

cycle

s %

Machine no 7 Repeater drum Drum no upper end faliure Tension Break Clearer cut Splice Cut Red light Repeater Problem Identified

(.1-.2)% (3-4)/100km (0-75)/100km (0-20)% (2-3)% (0-15)%59 20 0 25.8 20 100 120 Splicing assembly jam

Increased 43 457 16.8 117.4 7.1 100 171.9 Upper end Faliure (1st july,2015) 47 38 16.8 1212.1 13.9 38 151.9 gauge voltage

38 8.5 0 61.8 34.7 41.7 79.6 splice faliure40 7.5 0 67.5 21.2 12.5 67.5 splice jam59 0.6 7.9 79.4 9.1 6.5 29

Decreased 43 3.5 4.9 39 1.2 3.7 15.3 (2nd july,2015) 47 0 0 43.2 4.5 1.1 7.9

38 0.8 4.8 115.9 7.4 3.3 2440 1.1 1.5 62.5 17.9 1.4 20.9

1st july 2nd july05

10152025303540

33.6

27.4

Reduction in average repeater cycles after main-tenance (m/c no 7)

Date

Aver

age

Repe

ater

cycle

s

Machine no 7 Repeater drum Drum no upper end faliure Tension Break Clearer cut Splice Cut Red light Repeater Problem Identified

(.1-.2)% (3-4)/100km (0-75)/100km (0-20)% (2-3)% (0-15)%29 0 5 182.7 20.7 23.7 62.1 Problem on panel

Increased 25 0 8.2 132 21 15.3 60.3 Entangled yarn (7,july,2015) 7 391.7 0 149.6 0 100 416.7 Upper end faliure

44 0 0 268.5 17.5 27.3 94.4 Gripper arm jam1 21 34.3 137 21.4 7.1 60.4 loop gate

29 0 3.2 107.9 5.4 1.8 16.1 Decreased 25 2 2.1 69 5.5 2 18.7 (8,july,2015) 7 0.5 5.6 61.7 7.6 1.6 21.7

44 1.2 7.9 71 10.6 1.2 25.91 0 5.7 78 8.3 0 21.4

7-Jul 8-Jul0

5

10

15

20

25

30

35

40 36

29.17

Reduction in repeater cycles after maintainanceM/c no 7

Date

Aver

age

repe

ater

cyc

les

27-Jun 29-Jun 1-Jul0

5

10

15

11

6 5

Reduction in abnormal drums(Rep% 40 & more) after maintenance(machine no. 7)

dATE

aBN

ORM

AL D

RUM

S

STUDY OF MACHINE

NO. 8 (AUTOCONER 338) BY SCHLAFHROST

Machine no 8 Repeater drum Drum no upper end faliure Tension Break Clearer cut Splice Cut Red light Repeater Problem Identified

(.1-.2)% (3-4)/100km (0-75)/100km (0-20)% (2-3)% (0-15)% Increased 3 16.7 840 0 0 42 137.6 Problem in Mother Board (20th june,2015) 7 0 246.3 73.7 5.4 91.4 121.9 Loop gate

52 5.1 256.1 81 3.7 8.8 142.6 Ballon control ring not in position23 406.2 12.4 86.7 12.5 100 162.5 Upper end faliure

Decreased 3 1.2 11.7 80.6 7.7 5.3 27.8 (22 june,2015) 7 0 2.1 75.6 8.6 0.9 16.1 52 0 3.3 63.1 7.1 1.18 17.5

23 2.2 7 45.7 8.2 8.2 28

20-Jun 22-Jun0

5

10

15

20

25

30

35

4034.6

26.73

Reduction in average repeater cycles after maintenance

Date

Aver

age

Repe

ater

cycl

es

Machine no 8 Repeater drum Drum no upper end faliure Tension Break Clearer cut Splice Cut Red light Repeater Problem Identified

(.1-.2)% (3-4)/100km (0-75)/100km (0-20)% (2-3)% (0-15)% Increased 19 2.3 7.8 128.5 27.3 8.7 44.8 Loop Gate not touching bobbin (4,july,2015) 51 30.1 8.9 125.5 19.7 46.5 148.9 Upper end faliure & splice assembly jam

58 8.6 3.4 62.6 41.6 39.8 79.2 Splice faliure46 2 11 59.8 8.1 14.6 58.6 Gripper arm jam

Decreased 19 0 2.7 66.1 7.3 2.4 19.7 (5, july,2015) 51 2.2 7 45.7 8.2 8.2 28 58 3.2 5 71.1 3.2 2.7 15

46 0 4.6 48.8 5.7 4.5 18.5

4Th july 5th july20

25

30

35

29.63

26.17

Reduction in average repeater cycles after maintainance

Date

Aver

age

Repe

ater

cycle

s

20-Jun 22 june (Af. Maint)

4-Jul 5 JULY(Af. Maint)

0

5

10

15

12

7 7

4

Reduction in abnormal drums (rep%40 &more)After maintenance(machine no 8)

Date

Abno

rmal

Dru

ms

28%

8%

10%

8%

16%

16%

10%2%

PROBLEMS THAT MOSTLY OCCURS & INCREASE REPEATER CYCLES

Loop gateBallon control ringMother boardUpper end faliureSplice cutsGauge cuttingEntangled yarn in bobbinBCM jam,gripper jam

• Loop gates should be opened and checked weekly

• Gauge voltage should be checked and set to standard weekly.

• Regular monitoring of abnormal drums should be done,& abnormal drums should be Handed over to maintenance and electrical persons.

• Positioning of balloon control ring should be checked weekly.

Conclusions

• Cleaning of lower half of autoconer should be done weekly as fluff gets accumulated there.

• Splice cuts should be checked on display & drums having abnormal splice cuts should be handed to maintenance.

• Suction arm should be checked weekly.