MUTATEC MACHCONER

MURATEC     MACHCONER     (7-7)

INTRODUCTION:

This machine is an individual spindle type automatic winder and performs one cycle of yarn joining in 9sec. It is a fully automatic  winder  can  be equipped with CBF (continuous bobbin feeder ), the AD(automatic doffer) and  the yarn length and data device.

SPECIFICATIONS:

                                   

Machine direction                                Right and  Left                        

 No of spindles                                     60

blower duct;                                         upward exhaust and down ward exhaust

Blower cleaner;                         LUWA type

Bobbin conveyor;                                  single line type

Winding traverse width;                       6inches           

Winding angle;

Winding  drum;                                     Normal wind steel drum

Winding speed;                                     800to1500

Slub catcher;                                       USTER ,  UPM , D3, & C3

Joining method;                                   Splicer

Splicer head;                                        Individual type

Tension disc;                                        Spiral

Tension  spring;                                    O.5

Tension disc cushion;                            Standard

Yarn trap;                                             5dia

Gate feeler;                                         4-5type

Balloon breaker;                                   Triangle

Magazine;                                             5 pockets 90 dia

Suction mouth tip;                                Comb

Cutter material;                                   Steel

Full package sensor;                             Diameter size

Full package winding dia;                      300 mm

Machine type ;                                     Round magazine

BALLOON BREAKER:-

1.It is used to reduce centrifugal force, tension and stretching (or) rubbing of spinning  bobbin  on the yarn layer  by intermittently braking the balloon  to enable high speed winding of yarn. To release maximum effectiveness from the balloon breaker, it is necessary to select  a balloon breaker appreciate for the shape, position, and directions of spinning bobbin.

2.Thees are available  in different sectional shapes including  circular, triangular and square. Each shape has its own advantages and disadvantages depending upon  the kind of yarn being  used. Based on  the data we have found that triangular breakers are best in terms of  sloughing prevention, variation in winding  tension at the start  and end of winding ,fluffing and fly generation. For coarse yarns on long bobbins of over 305 cm the square type is better.

3.A low installation position is suitable for  finer yarns and high position for coarse yarns.

                          

MECHANISM ;-

After yarn splicing is fixed, the yarn starts to run and the balloon starts to descend until the sensor defects the bobbin chase point. As yarn wound from the bobbin to a package, the bobbin chase point detected by the Sensor goes down and the balloon descends gradually. When the yarn is finished, the balloon pipe returns to the home position.

PRINCIPLE:

1. When the solenoid valve receives descending input, the  air flow from port of the solenoid valve will increase and balloon will descend. The descending speed is  controlled by speed controller.

2. when the descending  sensor detects  the bobbin point, solenoid valve will be off. Then the balloon will stop at chase point balanced by the compressed air in the cylinder.

3. Height: Allow installation position is suitable for finer yarns and

high position is suitable for coarser yarns.

RIBBON WINDING:

It occurs when the ratio bet the package dia and drum dials of simple integers, and the yarn winding is in such a way that it over laps repeatedly. With the surface drive winders such as mach coner .it is difficult to completely prevent. But it is possible to minimize ribboning by respective parts of each unit. It mainly effected by cradle pressure. Low cradle pressure is better for ribbon breaking. The following also effects the ribboning,

            1. Increase dish

            2. Ribbon breaker interval

            3. Tension‑(increase)

STEPS TO LOWER CONTACT PRESSURE:

     1. Reduce cradle weight

                        2. Remove cradle weight

                        3. Change the setting position of the reduce spring 

                        4. Remove cradle oil damper piston ring or)oil.

1.For cone packages ,yarn breakage’s in subsequent process due to ribbon winding tends to decrease when increase dish is apply to prevent concentration of contact pressure  on the larger dia side of the package.

RIBBON BREAKER INTERVAL:

With mach coner, ribbon breaking is actively performed by turning on and off the drum motor power to periodically change the rate of drum rotation and cause  slippage between the package surface and the drum surface. The on/off interval has to set to minimize ribbon winding.  Select the interval so that, at the cycle where the down interval is set longer than the up interval, the dispersion angle  of the resulting ribbon is over 60° and the number of bundles is less than 30. However, a setting combination of up interval : 1.0 sec or less and down interval 1.8 sec or more is meaningless because it only reduce rotation.  A reduction ratio for the minimum drum rotation by the ribbon breaker of 80 to 85 % is sufficient .

                                      min. Rotation

Reduction ratio  = -----------------  *  100

                                     max. rotation

WINDING TENSION, Tensioner .

           Adjust the tension with the dial. The dial units are from 1 to  11 with 11 as the maximum tension .

TENSIONED SPRING SPECIFICATIONS :

  By selecting different spring combinations depending on the type of yarn, a wide range of tension settings are possible .     

OPTIMUM SETTINGS OF WINDING TENSION :-

   Generally speaking 8 to 12 % of the strength of a single yarn is the optimum winding tension. However, if the yarn strength varies greatly, measure the yarn strength 20 times, exclude abnormal values and use 8 to 12 % of the lowest value of the remaining measurement as the winding tension .Single yarn strength vs. Lea strength.

Yarn strength  (g) = lea strength ( KG ) ÷ 0.125

TENSOR SPRING SPECIFICATION AN TENSOR DIAL RELATION SHIP:-

  The relationship between the dial scale and the tension at a winding speed of 800, 1.000 and 1.200 m/min for respective spring. The  tension at the end of the winding is about 1.5 to 1.9 times that of the start.

DRUM SPECIFICATIONS :-

   It is possible to wind a package with a 4°20’ TO 9°15’ winding angle and a drum of 1.2: 1, but the wound shape on the end f the small diameter side of the package will not be good. When the wound package is re-wound in the process , however, the sloughing an yarn breakage will tend to be less. On the other hand , if a dyed package of 3°30’ winding angle is wound with a drum of 1.5, 1, ribbon winding trouble will increase.

WAX DEPOSITION :-

   Wax deposition is adjusted by controlling the in an out of the guide pin by increasing or decreasing the number of adjust washers.

  yarn count      number of washers

    0-19                         0

   20-39                        1

   40-79                        2

  80max                        3

SELECTION OF WAX  ( PARAFFIN )   

   

   When selecting wax, the following conditions should be taken into considerations. 1.Type of yarn  2.temperature  3.requrement to each yarn .

PROPER DEPOSITION OF WAX ON YARN :

The proper deposition of wax to each yarn should be known first . 0.5 to 1.5 g/kg of yarn is the optimum range, i.e. 0.05 to 0.15% wax. If this range is exceeded, the resistance to untwisting is naturally increased friction resistance and coagulation of the mixed yarn. A Friction resistance and shearing resistance are also inroads by the accumulation of wax on the surface of the friction resisting surface. When knitting. If the deposited of wax is 0.05 and 0.15%, the yarn will be judged as having been adequately waxed. This s because the friction coefficient of yarn with adequately waxing is 40 to 50 % lower than that of the yarn without waxing.

Accordingly, excessive waxing can do more harm than good. By waxing evenly in small quantities. yarn will be able to keep up with future knitting machines that will run at even at higher speeds .

CAUSES OF SLOUGHING :-

1.Number of coils-42%,  2.winding speed-17%  3.Height of balloon breaker-13%    4.Hardness of spg bobbin-12% , 5,Correlation between balloon breaker height and no:of coils- 4.5 %  6.correlation between winding speed and no: of coils -4% ,others - 7.5%.

CONTACT PRESSURE REDUCER :-

   The cradle contact pressure is reduced gradually as the package becomes larger. It is also possible to change the spring pressure by changing the setting of the eccentric hook.

RIBBON BREACKER :

 As the ribbon breaker of   MACH CONER, ON OFF  operation of  the drum motor  is repeated  periodically  to cause slipping  between the drum  and the  package  and to prevent ribbon winding. As on  ON OFF contact of this  drum motor  circuit, TRIAC  is employed .

what is TRIAC :

It is the abbreviation of   Tri electrode  AC switch, which means  AC ON OFF  control  switch of the semi conductor  having three terminals . because TRIAC is  a non contact  switch, no arc is generated  at ON OFF    operation  and the life is  almost permanent.

What is ON OFF operation of TRIAC :

The gate of TRIAC terminal is  for the selection of  input conductance  or breaking. Accordingly, when a signal is supplied to the gate , the TRIAC is turned to ON (conducted).  And 107 V is supplied to the drum motor  and the motor runs. The setting  for ON  OFF of the gate  signal  i.e.  the frequency  setting of ON  OFF operation of  the  drum motor, can be  adjusted by  the knob  VR1  ( up interval ) and VR2 ( down interval)  in the control box. When the  gate  signal is cut off the TRIAC   is turned   to OFF , and the drum motor  comes to a stop.

MEASURES FOR HIGH SPEED WINDING :-

High speed winding, it is essential to minimize sloughing. It is difficult to remove sloughing completely with a slub catcher and this can adversely affect the quality of shipped packages. This section deals with the causes of sloughing an countermeasures

WHAT IS THE MMC/2 ?

The mmC/2 ( Murata master controller/2 ) is a working data management device that also has a fixed length winding ( winding yarn length control ) function. It is exclusively for use with the Mach coner and link coner.

           

The fixed length winding ( winding yarn length control 0 function converts the drum rotation of each spindle into pulses, and calculates the winding yarn length. When the winding yarn length reaches the setting valve , it out puts a full package signal to stop the drum from rotating ( a green lamp comes on )In addition to this fixed length function, the Mmc has at management functions . It collects working data for each spindle, and displays detail analysis data on its  large LCD display. The data can be out put using the built in printer.

Effective use of the mmc/2 allows you to understand the running condition of each spindle on the mach confer ( or link coner ) and facilitates machine management, and improves efficiency and yarn quality. The optional MONITOR allows group management of Machconers. It centralizes data from mach m/c into one location to where operators can instantly access it and monitor the operating condition of multiple m/c s. 

FEATURES OF THE MMC/2

  1.Large screen ( 40 letters * 16 lines ) . 

   2.Simple operation   

   3.Built in printer

   4.Many functions

Data is displayed graphically,  Many data analysis functions

Fine control over running conditions for each yarn type

Analysis the causes for poorly performing spindles

Interactive display. If you cannot understand the meaning of some at, pressing the ? key brings up the appropriate help screen.  

5.Five display languages

The display language of the MMC/2 can be set to English , German, Italian, Spanish, or Japanese.

SETTING  ( INPUT ) SCREEN

F10 ( initial settings ) ----- Factory name, m/c no: screen display language,  date.  

F11 ( m/c settings  )    ----- Yarn clearer types and option control for all  spindles.

F12 ( group settings ) ------ Group range and omitted spindles .

F13 ( yarn type stings 1 ) -- Yarn name, count, items related to fixed length  Items related to spg bobbin yarn length and items related to winding speed.

F14 ( yarn type setting 2 ) -- Package diameter control, BQC and deceleration                                                                            start             position

F16 ( shift settings ) ------- shift schedule and shift end print format

F17 ( CBF settings ) --------- communication

f18 ( AD ) settings ) -------- communications .

F10 Initial settings  :-- 

Factory -- The factory name appears on printouts and helps in organizing the printout data.

M/c no; -- The m/c no: name appears on printouts and helps in organizing the printout data. you must set this if the monitron/2 is connected .

Language - Select one of 1. English 2.German 3.Italian 4.Spanish 5.Japanese

Date ----- The date format is in Japanese style when japes is selected ( YMD ) Time ----- Set minutes first press the key then set hours. The seconds start             at o .

F 11 ( screen m/c settings )

Fx call spg - Does not function if o is input. If the no: of problem spindles                      displayed by F41 exceeds this setting , the red rotation length                           will come on.

OP call sp -  Does not function if o is input. If the no: of problem spindles                       displayed by F42 exceeds this settings, the red rotating light                             will come on. 

Target ----- The operation condition of the m/c is expressed by the expression                          on the face. The targets are :-

               Target SEF % : SEF% target

                  ;   YLW % : YLW%   ;  

                  ;   MIS % : MIS%   ; 

                  ;   RTI % : RTI%   ; 

                  ;   YEF % : YEF%   ;

CLEARER TYPE -

Control for the unit differs depending on the type of yarn clearer .MAC SP.

no of spindles-

Input the total  no of spindles disregarding spans .

F 12 Group settings :-

Group - Classification by group , regardless of span is possible .This is used for classifying conditions for different yarn types, and can also be used to classify conditions for yarns of the type. It is possible to have different settings for each group. Omitted sp set - Used for  spindles that are to be rewound. The spindles is driven, but the data does not appear .

F13 YARN TYPE SETTING

LOT NAME  -

Input the name used in the factory for the yarn . Looking at the screen or printout allows you to find out which type it is at a glance.

KIND O : NE1 :NM -Specify o:NE:NM or 2: tex. This is used for the calculation inside the MMC/2 .

CONSTANT -

This is used for calculations inside the MMC/2 .

YARN CONSTANT -The length of yarn wound by one drum rotation during normal winding. The MMC/2 uses this value to determine the fixed length. With the TEACH-IN function, this value is automatically obtained and need not to be input. However, it can also be input manually.

PACKAGE LENGTH-This can be automatically over written by inputting the package weight.

PACKAGE WEIGHT-Input the package wt less the wt of the take up tube .

BOBBIN LENGTH-This can be automatically over written by inputting the bobbin.

BOBBIN WT    -Input the wt less the empty bobbin wt .

WINDING SPEED-The winding speed .

DISTURB %    -Used in the ribbon breaker .

DISTURB ACC  -Winding speed acceleration time .

DISTURB DEC  -Winding speed deceleration time .

14 screen yarn type setting

package density-used FOR PACKAGE DIAMETER CONTROL CALCULATIONS . with THE  teach-in FUNCTION, this value is automatically obtained and  need not e input. However, it can also be input manually.

DIAMETER 1-     Splice delay is not performed until this winding diameter.

                                     (Control package)   

SPLICE DELAY 1  The splice waiting time after a yarn break .

                                     (splice delay)

DIAMETER 2  -    Until this winding diameter , the splice delay is performed delay is performed with splicing delay1. After this winding   diameter, the splice delay is performed with splicing delay 2 

SPLICE DELAY 2  - The splice waiting time after a yarn break .

EXCESSIVE CUTS-   A BQC alarm occurs when the no: of yarn breakage’s for a bobbin exceeds this settings. Remove the bobbin as it is faulty. Press the yellow button to reset the alarm .

NOT ENOUGH CUTS- If the no: of continuous wound bobbins without a yarn clearer   cut exceeds this value, the alarm comes on. The evaluation  unit or the detect head of the yarn clearer are faulty and   must be replaced. At this time, there is a possibility that  the package may be non clearing, so reset the alarm using the reset switch, then remove the package from the cradle and wind  a new one .

CRADLE LIFT UP DELAY     

-Delay lifting of the cradle after a yarn break for the            set time .

SPLICING WAIT -       When miss splicing occurs with out lower yarn, the unit considers that CBF is not feeding enough bobbins and stands by  for the set duration until the splicing starts. For the magazine type, set to zero .

REDUCE POINT OF SPEED

      - In the case that reducing the winding speed by yarn length on a bobbin, input the % of yarn length where you wish to start reducing the winding speed. when input 0% or 100%, the winding speed will not be reduced by yarn length.     

  

F16 SCREEN SHIFT SETTINGS

SHIFT END POSITION- Data is automatically accumulated at this time, printed out, and cleared .

SHIFT END TYPE    - When spindle data is printed, an asterisk will appear on the left of data that exceeds the target settings and on the left of spindles no: for which even one piece of data exceeds its target.

REPORT           - Freely select six items of data that you wish to view in the shift end print out .

F17 screen cbf settings

communication CBF -  Input the no: of yarn types supplied by CBF when the MMC/2 is equipped with CBF, and set it off when it is not included. If it is set off, the CBF data is neither displayed nor printed out. SQC TARGET /SHIFT - This is a target set value of the function called spin inspector with in one shift .

WHAT IS SQC ? BQC ( BOBBIN QUALITY CONTROLLER )

DETECTS OFF QUALITY BOBBIN FIRST AND THE SPIN INSPECTOR READS THE spindle no: information of which spindle the off quality bobbin was produced, and then transmits the data to MMC/2 .SQC records the no: of off-quality bobbin generation per spinning frame spindle and displayed by an operators request.

F18 SCREEN AD SETTINGS

COMMUNICATION AD 1 - Turn it on when the first ad cones with a communication function .

COMMUNICATION AD 2 - Turn it on when the second ad comes with a communication function .

COMMUNICATION AD 3 - Turn it on when the third ad comes with a communication  function.

REPORT SCREEN F2

F20 MACHINE FACES - The expression on the face expression five items of data about  the m/c .

F21 GROUP FACES  - The expression on the face expression five items of data about a group .

F22 SPINDLES FACES -:           ;            ;          ;          ;   ;     

                    SPINDLE ;

F23 PRODUCTION REPORT- Displays the production quantity for all groups at once 

F24 OA REPORT        - 40 ITEMS OF M/C DATA ,.

F25 GOA REPORT       -40 ITEMS OF group data

F26 SP REPORT        -40 items spindle data.   

F27 CBF DATA      --Displays the CBF data, alarm no: no: of alarms and current                                              alarm.

F28 AD DATA       - AD data, no : of troubles and currently displayed trouble

GRAPHICS SCREEN  

F30 MACHINE TREND GRAPH - Line graph for the machine data from the previous 10                                                     shifts ( select one of the 6 data items ). 

F31 GROUP TREND GRAPH   - Line graph for the group data from the previous 10                                                        shifts

                          ( ;   ;    ;   ;     ;   ;  ;   )      

F32 SPINDLE TREND GRAPH - Line graph for the spindle data from the previous