SLIVER LAP E 2/4 a
|
|
||
|
ENDS
UP
|
NORMALLY
UPTO 24 ENDS UP POSSIBLE.
|
|
|
COUNT
OF SLIVER FED
|
Ne
0.12 TO 0.18
|
|
|
|
(
FOR 36 ENDS UP SLIVER COUNT UPTO Ne 0.22 )
|
|
|
CAN
DIMENSIONS
|
400
TO 600 MM UPTO 1250MM ( HIGH )
|
|
|
WEIGHT
OF FEED
|
75
TO 120 GM/M
|
|
|
DRAFT
|
1.5
TO 2.0
|
|
|
LAP
WEIGHT
|
50
TO 70 GM/M ( 75 GM /M . Max )
|
|
|
LAP
WIDTH
|
250MM
|
|
|
LAP
WEIGHT
|
UPTO
13 KG = 28.6 LBS
|
|
|
WORKING
SPEED
|
UP
TO 65 M/MIN = 213 FT / MIN
|
|
|
DRAFTING
SYSTEM
|
4
OVER 6 PNEUMATIC ( DK2 MODEL )
|
|
|
POWER SUPPLY:
|
|
|
|
3
PHASE A.C VOLTAGE 440 / 400 WITH 50 CYCLES /SEC
|
||
|
4 H.P
MOTOR WITH 1440 RPM AT 50 CPS
|
||
|
COMPRESSED AIR : 1.0 CUBIC METER / HR. AT 7
TO 9 ATM.
|
||
Pressure hook setting with normal pressure 8MM
DRAFT:
Select
the draft on the basis of the gearing diagram. " adjust the draft less
zones " so that the
web is
slightly stressed
The
best method is to reduce the draft until a slight pile - up of the fibres
occurs. Based on the
measure,
increase the drart by one tooth on the change gear
BOTTOM ROLLER SETTING IN SLIVER
LAP
The
setting of the drafting arrangement in respect to roller distance and pressure
can be determined from the following table. the value " a " is equal
to 5% staple
|
Lap weight
( in gms/mts)
|
roller
setting main zone
|
roller
setting pre draft zone
|
pressure of lap
( atm )
|
top roller
pressure kg/cm
|
|
55
|
a+5
|
a+8
|
1.6
|
2.5
|
|
60
|
a+6
|
a+11
|
2.0
|
3.1
|
|
65
|
a+6
|
a+12
|
2.2
|
3.4
|
|
70
|
a+7
|
a+14
|
2.4
|
3.7
|
SETTING THE LAP WEIGHT :
The amount of the lap weighting can be set at the regulating
valve
|
lap wt. Kg/cm
|
setting
pressure
250 mm lap
|
|
10
|
1.8
|
|
12.5
|
2.3
|
|
15
|
2.7
|
|
17.5
|
3.2
|
|
20.0
|
3.6
|
|
22.5
|
4.0
|
higher the lap weighting , the harder &
heavier lap becomes
THE LAP CHANGE TAKES PLACE AS FOLLOWS:
COMANDER 1 . preselection ( length of lap
less than 1 metre ). swithches off the motor
indirectly and switches on the valves S1 and S2.
The machine stops
and the clutch K disengages.
The lapping
apparatus is disconnected, the lap is relieved.
Pistion X turns
the lap roller by 1.3 m and the lap is severed.
COMANDER 2. Final selection comes into
action. Desired length of lap and switches on Valve S3. .
Lap heads are
lifted and the lap is released.
The limit switch b5 is actuated at the same time.
LIMIT SWITCH B5 : Switches on valve S4 and S5.
Lap spool magazine
swings inwards, pushes the full lap out
and supplies Fresh lap spools . .
.
S Spool magazine on reaching its end
position actuates the limit switch b6.
LIMIT SWITCH B6:
Switches on valves S6 and S7.
Full lap which has been pushed
out is pushed aside. On reaching the end
of its
stroke, the piston V actuates limit switch B12.
LIMIT SWITCH B12:
Resets comander U1
COMANDER
U1 : Switches off valves S1, S2 and S3 again.
Clutch K
re-engages; severing piston X returns to starting position.
Lap heads grip
the lap spools, move down wards away from switch B5 and
the actuates limit
switch B14 .
LIMIT SWITCH B14 : ( adjustable )
Switches off
valves S4 and S5.
Now spool
magazine moves back away from limit switch B6 and actuates limit switch B13 . .
The return
motion of the magazine is thus delayed
by means of seizing relay D6 .
.
Until the limit switch B14 is pressed.
This helps to avoid the rubbing of lap
discs with the
spool magazine .
.
Spool
magazine moves back away from limit switch B6 and actuates B13.
LIMIT SWITCH b13 :
Switches on the machine again.
LAP LOADING:
|
PRESSURE
ADJUSTED
ATM
|
LAP LOADING
KG/CM2
( VERTUCAL )
|
LATERAL GRIPPING
FORCE OF LAP DISC ON SPOOL KG/CM2
|
|
1.5
|
207
|
75 KG
|
|
2.0
|
276
|
100
|
|
2.5
|
345
|
125
|
|
3.0
|
414
|
150
|
|
3.5
|
483 KG
|
175
|
The higher the lap weighting, the harder
and heavier the lap becomes. Excessive weighting, however , results in hairy
lap sheets which means that the layers of the lap stick to each other when
unrolling it.
CHANGE PLACES AND ITS EFFECTS:
a)
CALENDER ROLLER AND SHELL ROLLER SPROCKET
WHEELS:
The wheels alters only shell roller
speed. For calendar roller 24 t and 25 t
wheels are only possible, for lap roller only 76 t wheel is possible and for
shell roller 77t , 78 t and 79 t wheels are possible, but normally 78 t wheel
is preferred.
b)
BREAK
DRAFT CHANGE GEAR ( Wn )
this wheel alters the 4 th roller
speed ( alter it when you required high break draft ). Less number of teeth gives lower break draft.
Only 54 t to 65 t gear wheels are possible.
c)
FEED
CHANGE WHEEL ( Wa )
It alters the steel roller and creel
rollers speed. It effects tension draft
also. Less number of teeth gives higher
feed rate and more number of teeth gives lower feed rate.
d)
CALENDER
ROLLER DRAFT CHANGE GEAR :
It alters the tension between the front
roller and delivery calender roller .
less number of teeth gives lower draft between calender roller to front
roller and more number of teeth gives higher dreft between calender roller to
front roller.
e)
MAIN
DRAFT CHANGE GEAR ( Z1 ) :
It alters the main draft . less number of
teeth gives higher main draft and more number of teeth gives lower main draft.
f)
DELIVERY
DRAFT CHANGE GEAR ( 17 , 18 AND 19 ) :
It alters delivery rate. Alters only draft
between front roller to calendar roller.
SOME
SETTINGS AND ITS EFFECTS:
MAGAZINE SETTING:
1.
Clearance at
rear from spool centering wall is 1mm. This setting cantrols the spools come
freely from spool magazine to lap disc.
2.
clearance at
delivery side from spool to centering wall 5mm. This setting cantrol the spool
damage , and also good winding on the spool.
LAP DISCS:
1.
Insert rings
or bearing cover clearnce should maintain 0.5mm ( setting inside lapdisc piston
)
2.
Setting
between lap disc to lap roller with
spool position 1mm.should be maintained. This control lap edge position. This
setting is to adjusted by means of distance rings provided inner side of lap
disc chamber.
LAPPING APPARATEES WITH AUTOMATIC LAP
CHANGER “ AUTOLAP “ :
The lap weighting system consists of 4
cylinders with associated pistons and piston rods namely two long stroke
vertical cylinders for lifting and lowering the lap discs and two short stroke
horizontal cylinder for nipping the lap spools.
The lap discs have a short projections
for centering the lap spools. They are mounted in anti-friction bearings on the
lap disc shafts. The vertical cylinders are rigidly screwed to the inside of
the lateral frame members.
The horizontal cylinders for lateral
nipping of the lap form a self contained unit together with the guide heads.
These heads run in removable guide channels fitted into the lateral frame
members. All operations are controlled automatically and besides these
advantages , the pneumatic weighting system permits infinitely.
DRAFTING ARRANGEMENT:
The sliver lap machine model E 2/4a is provided with a DK2 drafting arrangement .
it have 2 pairs of fluted steel top rollers for better grip of fibres.
This comprises two
double nip assemblies consisting of two bottom rollers each topped by a rubber
roller, with a succeeding simple nip assembly. Each consisting of fluted bottom
roller and top roller. Each double nip assembly is followed by a drafting field
and preceded by a draft less zone.
The fluted roller pairs have the
advantage that can hold securely even the large fibber masses. Owing to the fibber mass being positively
pressed into the flutings, however , the delivery rate of the roller pair is as
much as 20 % higher than that calculated on the roller diameter and this factor
must be taken into consideration in
draft calculation.
TOP ROLLER WEIGHTING:
The drafting arrangement is pneumatically
weighed. A tube running under the
drafting arrangement on each side contains flexible nose which has an internal
over pressure and forces a row of pressure shoes down. Within the range of a weighing hook, this
takes the pressure from the shoes and transmits it over a draw bolt to the top
rollers. The compressed air to the
drafting system is obtainted from the compressor pipe line through a pressure
regulator. The three way valve helps to
cut off the pressure in the drafting system.
It permits weighting and relief
immediately with out affecting the pressure setting.
TOTAL DRAFT AND BREAK DRAFT:
When the total draft is greater than 1.5
the break draft should be kept as 1.3
in this case 45 t gear is to be fixed on the roller 4 and
46 t gear on the roller 6.
In special cases if a lesser break draft is
required it is possible to obtain . for
example a break draft of 1.22 can be obtained by fixing 48t wheel on the roller
4 and 1.15 by fixing 51 t wheel on the roller 4.
When the total draft is less than 1.5 a
break draft of 1.05 is recommended. In
this case 50 t gear is fixed on the roller 4 and 37 t gear on the roller.
SPOOL
DIMENSIONS:
SPOOL OUTER DIAMETER : 145MM
SPOOL LENGTH : 250MM
The diameter of the lap spool must not differ
by more than 1.0mm.
the cloth should over lap 10 to 20 mm.
Both spool and
cloth should coated with high grade Neoprene Adhesive such as balcome.
Cotton fabric =
240 gms/square meter.
SETTING THE LAP DISCS:
Both sides of the lap roller to the lap discs
clearance = 1.0 mm
width of the lap roller =
248 mm
width of the shell roller =
250 mm
CLUTCH:
The clutch serves to interrupt the
delivery from the lapping apparatus when severing the full lap. To ensure that
the opening and closing of the clutch are timed properly throttle discs 0.4mm
and 0.6;mm are fitted in the air line with the additional throttle discs
provided, it is possible to alter this timing.
COMPRESSED AIR:
The operating pressure must be at least 6
kg/cm2 at the inlet of the m/c.
Lap loading air pressure to be on no account more than 5 kg/cm2 is to be
adjusted.
SETTING THE BREAK:
The brake is fitted in to the v-belt
pulley on the main shaft and is operated by means of pneumatic cylinder .
As soon as the pre selected length ( 1 mtr
) less then the delivery length is obtained the break. This operated S8 for which air supplied by
means of special regulator with mono meter ( after necessary reduction in
pressure ).
TABLE GUIDES:
The guides knobs are adjusted in way to
approach the sliver to their neighbors tightly without running over each other
or pressing the slivers in the center wards.
TECHNOLOGICAL TROUBLE
|
TROUBLE
|
POSSIBLE CAUSE
|
REMEDY
|
|
1) Lap “ blisters “
|
lap roller turns
too fast.
|
Use large
sprocket on front lap roller.
|
|
2) Lap
“ hairs “ when
unrolling.
|
Lap pressure too
high climatic influences.
|
Reduce lap
pressure.
Climate: 50 to
60% RH at
23 to 25 °c.
|
|
3) Ribbon is drawn
down between back lap roller & lap disc.
(Or)
ribbon has
excessively thick edges.
|
Ribbon guide is
set too wide.
|
Set
ribbon guide closer;
shift
guide stud on table accordingly.
|
|
4) Ribbon
leaving drafting arrangement is wavy.
|
Pressure of
drafting arrangement too low.
(Or)
Drafting
arrangement is set too close.
|
Increase
the pressure.
Set
wider.
|
|
5) Ribbon is
cloudy.
|
Pressure of
drafting arrangement too low.
(Or)
Drafting
arrangement is set too wide.
|
Increase
the pressure.
Set
closer.
|
|
6) Ribbon shows
cloudy or wavy length wise strips.
|
The slivers run
over each other on the table.
|
Realign
the guide knobs.
|
TROUBLE IN MECHANICS & PNEUMATICS:
|
1) Guide heads
work very heavily.
|
Supply line
pressure too low.
( Or)
filter clogged.
|
Overhaul the
system.
Clean the
filter.
|
|
2) Lap discs
close only after lowering.
|
Supply line
pressure too low.
(Or)
rubber seals are
too dry.
|
Overhaul the
system.
Increase rate of
oil lubrication and lift and lower lap discs about 20times. Then reset lubrication to normal.
|
LIMIT
SWITCHES AND THEIR FUNCTIONS:
B5 : - This must confirm the highest position of the lap heads.
This switches on valves
S4 and S5 . the spool magazine
swings in, pushes the lap out and operates
the limit switch B6 in its end position.
B6 :-
This must operated, when spool
magazine swings in. lap shifting takes place. This switches on valves S6 and S7
. the shifting cylinder operates the limit switch B12 in its end position.
B12:-
This is operated if the lap is pushed
away, i.e. , if the shifting position is fully retracted. This resets the
commander contacts U1.
B14 :-
As the guide heads come down, limit
switch B14 must be over run. Set the switch
far down so that the spool is no longer touched by the magazine as this swings
back.
B13 :-
This must operated, when the spool
magazine swings out. This switches on
the machine again. Energies the timer D11.
B8 :-
Full lap limit switch. It is to be set
at full lap plus 10mm up.
B7 :-
As soon as the lap heads have reached
their lowest position ( with spool ) they actuate limit switch B7 . the latter
keeps the machine switched on and transfers the switching-off function to the
time relay D11 . this time relay ( d11 range of adjustment 0.2 - 5 sec.) stops
the machine again if the lap heads do not raise correctly i,e if the lap does
not wrap itself round the spool.
B9 :-
If the spool is not loaded into the
machine this switch off the machine and indicated by the glowing of yellow
lamp. This switch is set with a gap of
0.7mm between the spool and guide head.
If the gap is set at 0.6mm, the switch will not actuate.
B11 :-
This must be operated , when the front
door is not closed.
B10 :-
This must be operated, when the lap deliver
is full.
B15, B16 :-
Safety switches for lap machine doors.
B18, B19 :-
When the calendar roller is over - lapped
or if the thickness of the lap is large these switches off the machine.
EMERGENCY SWITCH B1 :
This has three positions and may be
used to initiate a fresh changing
operation in the event of a fault.
Position 1:
Automatic operation.
Position 2: The
lap heads are raised and the spool magazine swings in.
Position 3: The
lap heads are raised but the spool magazine does not swing in.
Minimum pressure switch B20 :
The minimum pressure is controlled by means
of this switch B20 mounted in the pneumatic control panel.
TIMERS:
Timer D11 :
For controlling lap heads lifting , i.e.
after main motor is started, if a layer of lap is not formed over the lap spool
with in 5 seconds. This timer switches off the machine.
Timer D12 :
Normally both the declutching and detaching operations should happen
simultaneously, but due to some mechanical snag at certain times valve S2
operates before the valve S1. I.e., detaching operation takes place before
declutching operation, which causes the front bottom calendar roller shaft
breaking . to avoid this problem, the timer D12 is added which makes the valve
S1 operate first and then the valve S2 there
by declutching operation takes place first and then the detaching and
unloading operations takes place.
SOLENOID
VALVES:
Solenoid valves S1 to S10 :
During normal operation the valves S1
to S8 are dead, except during the changing operation. Valves S1,S3,S5 and S7
are opened when dead ( i.e, air is allowed to pass through ). Valves S10 and
S11 has no control function. They serve only to prevent accidents in the event
of power failure. If the guide heads are raised and the lap discs are opened ,
in the event of power failure the valves S10 and S11 will close, so that the
air cannot escape. The lap discs therefore remain open and the pressing heads
cannot descend.
Solenoid valve S1
: clutch and break of the cut off cylinder.
S2 : bottom of main cylinder through S11 and
front of the cut off cylinder.
S3: top of the main cylinder.
S4: Magazine swings in.
S5: Magazine swings out.
S6 & S7: Guide cylinder for lap shifting.
S8: Brake.
S10: For slow descending of guide heads whenever
power failure.
SL / RL DOFFING CYCLE
PRESELECTION COUNTER
!
S1 ON
!
CLUTCH OPEN
!
S2 ON
!
COUNTER FINAL SELECTION
!
S2 OFF
!
S3
ON
!
MAGAZINE LIFT
!
B5
CLOSE
!
MAGAZINE SWING LAP OUT
!
LAP TRACK MOVE
!
B12
CLOSE
!
COUNTER RESET
!
S3
OFF
!
SPOOL CATCH
!
B11
CLOSE
!
MAGAZINE
DOWN CLUTCH CLOSE
! !
B7
CLOSE M/C RESTART
!
S1 OFF
SLIVER LAP / R.L
MACHINERY AUDIT CHECK LIST
|
Date :
|
machine no:
|
checked by:
|
|
|
|
|
|
OBSERVATIONS
|
CHECKS
|
REMARKS
|
|
|
|
|
|
1. Lap roller condition
|
perfect /
scratched
|
|
|
2. lap guides
Right hand side
left hand side
|
|
|
|
3. stop motions
at feed,
drafting
|
working / not
working
|
|
|
4. draw box condition
a) top rollers
b) top roller end bushes
front middle back
|
|
|
|
5. top clearers
|
proper / always
clean (not working )
|
|
|
6. bottom
clearers
|
proper / always
clean (not working )
|
|
|
7. guide plates
|
good and in
place / misaligned / with scratches
|
|
|
8. feed table
|
smooth / rough /
scratched
|
|
|
9. table
calender roller condition
|
smooth / rusty /
peeled / jammed
|
|
|
10. selvedge guides
fornt
back
|
good and in
place / misaligned / with scratches
|
|
|
11. calender
roller
|
smooth / rusty /
peeled / jammed
|
|
|
12. lap roller condition
front
back
|
perfect
/scratched
|
|
|
13. lap
disc-surface eccentricity value
|
|
|
|
14. door limit
switches
|
working / not
working
|
|
|
15. air leakage
|
no / minor /
major
|
|
|
16. gear wheels
condition
|
perfect / worn /
semi broken
|
|
|
17. chain
condition
|
perfect / slack
/ worn and noisy
|
|
|
18. “v” belts
condition
|
perfect /
slightly worn /split
|
|
|
19. number of v
belts
|
all / one less /
two less
|
|
No comments:
Post a Comment