SAVIO AUTOCONER TECHNICALS DETAIL AND FUNCTIONING

SAVIO AUTOCONER ESPERO -L

Model                  : Espero  L , M, E, I.S

No Of Heads            :Up To 60

Winding Speed     : Continuously Variable Speed From 400 To 1600 Mpm

Clearers               :Uster Upm, D5, Loepfe, Keisokki

Waxing  Unit           : Interference  Type

Yarn Tensioner         : With Two Tensioning Sections

Feed                   : 32 To 65mm  Dia Bobbins  With A Length Of  180 To 320

Feed Cylinders         : Special Cast Iron  Type  Unlimited Life

Take Up                : Packages From O  Degrees To 9 Degrees

Package Holding Arm    : With Package Taper Increment  Feature

Automatic Doffing      :  By 1 Or 2 Traveling  Trolleys

Braking               : Instantaneous  Package  Lifting , With Package Braking                             Independent Of Cylinder Braking

Centralized Adjustments : For tensioner, Counter Weight, And Clutch  On Package                              Holding Arm, Splicer  Feed Pressure, Speed, Meterage                                And Anti- Repeater Cycles.

Adjustments On Each Head: For Waxing, Splicer, Precleaner, Package Taper                                     Increment , And Balloon Limiter.

Bobbin Feed             : Manual Or Automatic

Package Tube Feed       : Centralized  Automatic  From 1 Or 2 Feeders Located 

At The Head Stock Or Individual Bobbin Bins At Each Head.

Connection To Spg. Frame  : Through Ramps Which Collect  Bobbins Directly  From Spg .

Air Exhaust              : Ducts Under The Floor.

Suction Unit - Blower    : Programmable  Travailing Type.

Package Discharge Conveyor: Single Conveyor Or A Paired Conveyor .

Inspector Control        : Control Unit For  Programming Machine Parameters                             And For Display  And Printing Of Production And                               Efficiency Data. This Unit Also Monitors  The M/C                               For Any Malfunction.

Elios                 : Setting And Collection Of Centralized Data  For A                                 Number Of Machines On Personnel Computer.

The back of the  head stock  contains the following :

1.an electrical power out let  - 220 V 400A used to only   net test instruments.

2.The access door  to the  yarn collecting box.

3.Electrical equipment and  its  master switch.

4. The filter grill  for the trains former  cooling air.

5.The green button which activated the package conveyor   at any point during its operation .

6. The photocell  which shuts down  the package  discharge  conveyor.

Control panel : this is located  in the center of the control board  and includes :

1.the illuminated strait button

2.stop button

3.selecting switch for traveling blower - suction unit;

4.selector switch for machine lighting

5.a yellow lamp which signals that the pressure  switch has been tripped .

6. Hour meter

7.emergency stop button

pneumatic  control panel: the pneumatic control panel includes  the following  control devices

1. Air pressure on yarn  tensioners   0 to 60 kPa

2. Air pressure  on counter weighted  0 to 400 kPa

3. Air pressure on clutches  0 to 400 kPa

4. Air pressure on  air splicers  0 to 1000 kPa

5. Air pressure  on suction units  0 to 10 kPa

no of motors  in the head stock :

1. Suction unit motor

2.cycle cam shaft gear motor

3. Package discharge conveyor   reduction motor

4. Tube discharge conveyor  gear motor.

WINDING UNITS :

Espero wdg units are completely  independent and  are equipped with  individual inverter controlled motors. Each wdg unit  is made up of  the following basic elements .

1.A central body  containing the  mechanisms  which  drive  the auxiliary          devices  mounted on  the side of the  head.

2.Cylinder unit  with motor

3.Package holding arm

4. Foot with bobbin holder plate

Drive mechanism box :

All drive mechanisms in the box  are driven by the gear wheels  which is spliced to the cycle cam shaft  and transmitted  through the gear wheel .the cycle shaft runs  the entire length of the machine  and is driven from the gear box. the gear wheel is constant motion , when a cycle is to be carried out  the solenoid valve releases  the pawl which then engages the   rotating gear wheel thus the crown wheel is put into motion, together with chain which connects the cam units  and also splicing unit. when a bobbin change is required a solenoid valve  frees the pawl  and the bobbin change cam shaft is  put in to rotation. the idle type is controlled by the roller type positions .

package holding arm :

It is equipped with  interchangeable centers  which accommodate different  types of tubes. the center is  equipped with mechanical element   which rotates the  tube   while the  first few turns of yarn  are being deposited .

NOTE : when  tubes  with a taper  of 5deg 57’  4 deg 20’ and 3 deg 30’ are being used  the center is  fitted with a  lint breaking device. The other center is  equipped with a pneumatically  actuated  shoe brake which the package .

counter weight :

The package holding arm is  equipped with a counter weight unit  powered by a pneumatic piston. the function of  this is to reduce the  contact pressure between package and cylinder. the air is centrally adjusted in the head stock.

Clutch :

The arm is equipped with a clutch  which absorbs vibration. The clutch consists of a piston which exerts a braking action on a part of  the arm , thus reducing the vibration. its pressure is centrally adjusted in head stock.

Package taper increment :

This is choosed on type of yarn, type of tube and eventual use of package this can be vary from 0 deg to 7 deg.

Package diameter  calibrator :

It is located  on the right side of the arm. It is used to  obtain  given  dia of  package  instead of given package .

Arm Lifting :

This is lifted by a piston  which is actuated by a solenoid valve. The solenoid valve  uses the arm  equipped  with  pawls  to raise  the sector  which  forms a part of  the  arm.

Modulation :

The movement of the package  required to  offset  the deposit  of  yarn loops  on  the  package is  provided  by  element   powered  by  a  small motor  mounted on the arm. The arm imparts the modulation movement  to the package  through  a cam  and the lever. The micro switch  ensures that   the arm always  stops at the same position  with respect to the cylinder  when the head is shut down .

Nozzle To Package Distance Compensatory : 

An automatic  distance compensator is  fitted on the left side  of the arm . this  regulators  the distance between  the package  yarn   suction nozzle and the package it self. This unit ensures Max Efficiency of the   suction nozzle .

Inverter :

The Inverter  box  which  contains the power supply   board for the  cylinder motor, is located  on the left side of the  arm.

Cylinder  unit :

The cylinder unit consists of a  box  from which the  following elements are  suspended : the yarn guide cylinder, motor, yarn guide, yarn  brake  and tangle feeler. The motor drives the  cylinder through a clogged belt . the speed of  the  cylinder is measured by  means of  an  infrared sensor  which reads the perforated disc. The wdg speed for  all the heads  is set  on the inspector control unit. The speed is  graduated from 400 to 1600 rpm. the cylinder is braked by a inverter controlled  motor. The sensor  also measures the meterage of the yarn  which is being wound  on the package . the desired  meterage is set on the inspector control unit. The yarn guard and yarn brake are installed infront of the cylinder. The tangling feeler  rod is connected to the lever. If a tangle forms  on the cylinder, the  rod is moved by  the tangle, and the lever is  shifted, tripping the micro switch  .the head cannot start until the tangle  has been  removed.

Clearers :

Only electronic  clearers  can be used on espero machines. the yarn  inserter and  the cleaning   jet  are  standardized  on all types of  clearers installed  on the espero machines .

yarn tensioning unit :

It is made  up of  two yarn tensioning  sections  mounted on a supporting element. Each  tensioning  section is equipped with  moving pressure  washers  and  counter  washers. The pressure  exerted by the  washer  on the  counter washer is  provided by the piston. This pressure can be centrally at head stock . a piston which is fed from main compressed air  line moves  the washer towards the right  during knotting cycle, this movement allows for easy cleaning between the washers and assists insertion of yarn  to be spliced . a nozzle  is located above  the first yarn  tensioning  element .the function of the nozzle is to capture the yarn after  it is cut by the clearer. During this cycle the nozzle moves forward to extract the yarn and remove any dirt  which has collected on the tensioning washers.  The nozzle  moves towards the  inside to insert the bobbin yarn end in to the splicer. Finally   after  the splice has been  carried out, the nozzle returns to  the winding position and holds the yarn during the cylinder start up. This holds the yarn under  a tension which is similar to the  wdg tension   even during startup , thus  reducing the possibility of yarn curling  and undesirable clearer cuts.

NOTE: for best  performance of the  tensioner,  do not  adjust the compressed air  below 50 m bar.

Waxing unit :This unit is mounted  on the same supporting  element as is used   to hold the yarn tensioner. The waxing unit is also equipped with  two tensioning elements   the wax disk is  rotated by a motor  at a speed of 10 rpm . The waxing unit is opened by a piston  during the  splicing cycle .

Intermediate yarn control :-

This unit consists of  the yarn placement arm  yarn feeler , scissors and pre - cleaner .

yarn  placement arm:-

During bobbin changing this  unit carries  the yarn end from the  new bobbin in to the feelers and scissors .

yarn feelers :-

This unit checks for the   presence of yarn  during  every cycle .   this unit  consists of  the yarn gripper unit and the yarn feeler . the lever is connected to the  internally mounted lever. The yarn feeler rod is  connected to the lever. The pneumatic piston moves the  lever which strikes the   second lever  and grips the yarn. The continuing the movement carrying gripped yarn its the feeler rod, the yarn feeler is  shifted by the  yarn together  with the two levers mentioned above. If there is no yarn present  , the rod  is not shifted  in this case, a movement is created  which, by means of the lever   actuates the bobbin change micro switch.

Scissors :-

The scissors perform two cuts  at every cycle :

1.the first cut is carried  during the normal  splicing, this  cut allows  the yarn  tensioner nozzle to capture the  cut end .

2.The second  cut is carried out  during the  bobbin change cycle   , this cut  allows  the bobbin change suction nozzle to  capture the cut end .

pre - cleaner :-

The opening  of the   pre  cleaner  can be adjusted to a width of  0.5 to 2.2 mm. During  the  cycle,  the  pre cleaner completely to discharge any  tangles  which have been sucked by the  yarn suction nozzle. This is opened by  compressed air .

lower yarn control unit :-

This unit consists of a yarn positioner,  scissors,  balloon limiter and anti curl rod .

The yarn positioner :

It keeps the  n yarn  centered  on the bobbin  during winding . the yarn is guided in to  the  yarn  positioner  by the yarn placement arm  during the  bobbin changing cycle .

scissors :

It cuts the any tangled  yarn end   on the discarded  bobbin during the bobbin change cycle. The scissors  are  moved by  a rod  which directly  connected to the mechanism .

balloon limiter :

It is used  to process S or Z  yarns .  this height is adjustable .

The anti curl bar :

It consists of  a bent rod  which rests on the bobbin  tube during  the cycle  it prevents the  formation of  curls  by maintaining the proper  tension of the yarn  during acceleration and deceleration. It is operated by a solenoid valve .

Bobbin holder unit :

It consists of  arrogating  plate  with three pegs  which hold the bobbins  an expeller  is located  on the right side of the holder. The bobbin  which is  being un wound  is  held on  the bobbin holder plate. When a bobbin is  being changed, the holder rotates  120 deg  to bring a  new bobbin  to the feed position, at the same time the expeller discharges the empty tube . the bobbin holder is controlled by the  cam ‘Q’ on the cam set when the yarn feeler  no longer detects   the presence of  the yarn  from the bobbin .

suction  nozzles :

Moving suction nozzles are  used  to capture the  yarn. These are arranged on the left side of the   head .

1.package suction nozzle  with double  yarn capturing  action .

2.suction nozzle which catches the bobbin  yarn  and inserts in to the splicer  the unit is equipped with economizer  and triple  yarn capturing  action to minimize  the accidental formation  of yarn fragments .

3.bobbin yarn  suction nozzle  located above the  bobbin magazine .

4. Yarn  tensioner suction  nozzle , this nozzle  captures the yarn  after it has been cut by the  clearer .

The suction nozzles are connected   to the suction box through the fitting and the tube  while the nozzle is  connected  to the tube. The package yarn suction nozzles located at the end of the pipe is equipped with an economizer  of the intake air. This economizer is  driven  directly  by the mechanism box. The nozzle sucks the yarn  from the package  during the reversal of the cylinder  movement the other nozzle  sucks the yarn from the just above the ceramic yarn positioning element. After catching the yarn ends the two nozzles  assisted by the  tensioner suction pipe, insert the  two yarn ends in to the splicer .

Twin Splicer -

A mechanical splicing system :

The twin splicer  which operates  on a purely  mechanical system. One of its advantage is  to control  and  guide the  yarn during  the entire splicing operation. The untwisting  and re twisting action  on the yarn is carried out  between  two self compensating   interfaced disks  which can  adapt to all type of  yarn diameters. Three adjustments must be carried out  on the twin splicer :

UNTWISTING -  RE TWISTING  - DRAFTING .

the presence of wax does not effect   the characteristics of  the splice .

splicing cycle :

In brief, the splice is carried out  with the following procedure . after the two yarn ends  have been introduced  between the disks, they are un twisted and drafted. The yarn ends are  brought together to create the  central part of  splice and excess yarn  at the ends is un strong to detached. The yarn ends and spliced ends  are then  joined together and the yarn is re twisted   the disks   are then opened and  the splice is extracted .

Twin splicer units :

Introduction of  yarn ends : the package yarn suction nozzle and  lower yarn suction nozzle insert in to the  splicer, before the yarn is  introduced , the package yarn nozzle opens the  cover by hitting  the lever, the cover closes after splicing .

external clamps :

These are one on the lower side  one on upper side  are used to draft the ends  for splicing. The  lever which is actuated by the movement of the  clamp  holds the yarn  as it is untwist  on the lower part of the unit.

Ripping grippers :

The grippers  with draw the  yarn to be  un wound at  the end of the plates  and rip the yarn ,  at the end of their travel  the grippers open and free  the yarn ends  so they can be removed .

twist inhibitors :

These mounted  on the plate separate the section of the  yarn to be un strong  from the yarn to be left hole ; they also prevent the  twisting of the  yarn  to be left whole  .

Movement of the plates :

The plates  are moved  through the lever. The following  is the  sequence of the  operation of the plates :

1.The yarn ends are introduced  parallel to each other  between the plates .

2.The plates are brought together .

3.The plates rotate to untwist the  yarn ends  and at the same time   the two threads are brought together   by four pegs  , while they are being drafted   by the external clamps .

4.The twist inhibitors  operate as described above .

5.The combs on the inside of the  plates are actuated .

6.The plates open slightly and turn in the direction  opposite  their direction during  UN twisting. This twists the  yarn and completes the splicing .

Adjustments :   

Package holding  arm : insert a tube between  two centers   that the tube  is  properly  held between the centers , make sure that the  moving center extends  approx. 4 mm more than  it is extended   when it is  with out tube .

Package Lifting  During Splicing :

The package must not be lifted  5 to 12 mm during splicing . max. Raised position of the   arm is  182 .5 mm +/-   .

Cylinder unit :

1.the tangling rod is adjusted  to a distance of 0.5 to 1 mm.

2.The micro switch is adjusted  to trip and  shut down the  head  when the tangle feeling  rod is with in  1.5 to 3 mm from the cylinder .

3.The yarn guard must be  set at a distance of 1.5 to 2.5 mm from the cylinder

4.Speed sensor is set at a distance of 2.2 to 1 mm.

Waxing unit: the alignment of the porcelain guide element  with the porcelain element is adjusted at a distance of0.5 mm.

Adjusting the quantity of wax :

The amount of wax  can be adjusted by  inserting  spacers under the base of the yarn guide. This can be  applied up to a max. Of 0.6 mm, which  is equivalent to  4 spacers  with a thickness of  0.15 mm each . this amount of wax varies  from 0.8 to 2.2 % .

yarn feeler :

1.Micro switch  contact must open in the range of  0.5 mm to 1.5mm distance .lower yarn control : balloon limitor : the distance is 25 mm   in between  the balloon limit and  top of the bobbin .

SUCTION UNIT :

The suction unit  provides the  vacuum to the  suction nozzles  on the heads and the bobbin loaders. The unit is driven by a motor  through a V belt  the unit is fitted with normally  pulleys of suitable diameter  to obtain a pressure of  about  6500 Pa. The  vacuum  level is indicated  on a vacuum gauge  installed on the pneumatic  control panel. A no of different pulleys are available   to provide the  different vacuum levels .           

       

ISPECTOR CONTROL :

Main features : it is a completely computerized  system  used for  presetting and  monitoring the entire  winding process  on the ESPERO  winder.

 It does the following

1.Allows  to preset  both  the machine operation  and  production data .

2.collects, process  and displays  the production data of the  wdg  heads  , doffing trolleys, tube magazine and  bobbin loader.

3.Centralizes all m/c alarms.

4.moniutores the trollIes operation .

TECHNICAL SPECIFICATIONS :

Micro computer system :for presetting and  acquiring  data  and monitoring the espero machine  operation .

customizing : the user can customize  the system  by means of the following  programmes .

                        EO  ---   EBO ----   EB1 ---  EB2

Entering and requesting of data :

By means of a special key board mounting  on  the front pannel.

Printing of data :

By means of a built in printer   in the central control unit .

key board :

25 characters, numbers o to 9, letters A,B,C,D,E,special symbols  CL ,.,*,/,RETURN ,+,-,->, <- , and paper line .

Display :

High efficiency  liquid crystal display ,contrast ratio  control by acting on the  potentiometer  located on the lower motor board  inside the electronic rack.

Key :

when this key is set in its neutral position , the key board is  locked and no data can be entered  through it . only  previously data can be requested .

System autonomy :

Should a mains failure occurs, the system will maintain  the processed data for a Max of 100 hours  by means of a 3.6 battery V located in the electronic rack . Programmes E0, EB1, Eb0, EB2 are stored in non volatile memory. If the printer  circuit board is removed  from the electronic rack , the production data will be  maintained memorized  by the system  for about 10 min.

Power switch :

Power is turned  on by pressing  the power switch, as a rule , the system  should be left turned on. The green led is go on to indicate that system is on line .

Fuses :

The ispector  control system  supply circuit is  protected by fuses .the fuses is  a T type  , 1.25 fuse.

Printer :

Print data on electro sensitive paper .

leds :

Led A.C. line indicates  that alternate current circuit is  connected .

led D.C  supply indicates that the direct current circuits are  connected .

PROGRAMS :

E     to enter

Eo :time , shifts

EBO : machine data

EB1 : working data

EB2 : lot end

   

C          to print

CO : to print by means of program  EO

CBO :to print by means of a programme EBO

CB1 : to  print by means of a programme EB1

C1 : production data of a given machine  section

C2 : no of cts of a given machine section

C3 : cycle ratio limit  of the  wdg heads

C4 : data of the peripheral units

C5 : efficiency range of the   wdg heads

C6 : no of stop motions of the wdg head

C 6A : no of alarms of the peripheral units

C7 : type of alarm of the peripheral  units

C 8 : package meterage of the given  wdg head

C10 : soft ware version  installed  on a given peripheral unit .

D   to display

DO : data entered by means of a programme EO

DBO : data entered by means of a programme  EBO

DB1 : data entered by means of a programme EB1

D1 : production data of a given machine section

D2 : no of cuts of a  given machine section

D 3 : cycle ratio limit of the wdg head

D4 : data of the peripheral units

D5 :  efficiency range of the  wdg heads

D6 ;  no of stop motions of the  wdg head

D 6A : no of alarms of the peripheral units

D 7 : type of alarm of the peripheral unit

D 8 : package meterage of the  a given wdg head

D10 :  soft ware version  installed on a given  peripheral unit .

other commands :

CD :    to print  a report  of the  current shift

CA : to print a complete report of the previous shift

EAO : to reset the data

A1 : to display or print  a list of  established commands .

CHANGES :

To change any one of the  entry of the  programmes, proceed as follows .

press CL - PROGRAMME MODE - RETURN keys.

Press repeatedly  the RETURN key until  the data  to be changed  is being displayed. to back to the  previous  data , just press the  <- key . type the new data thus  deleting the previously  entered one . press repeatedly  RETURN  key until the programme is terminated. to interrupt any  printing procedure  press the /and RETURN keys.

DEFINITIONS :

AVERAGE SPEED :

The average value of the  bobbin unwinding speed. In case of a constant the latter is coincident  with the  average speed .

BOBBIN METERGA :

The bobbin meterage  is the value  in meters  of the  length of yarn wound  on a full bobbin.

Percentage change:

The percentage change  is the value, being  100 the bobbin meterage , to which the slope of the  speed variation  is changed .

initial speed :

This is an absolute  value of the speed  at the unwinding  start . this value must not exceed  1600 M/min.

Percentage of the initial speed :

This is the  percentage  value of the speed  increment with  respect to the unwinding speed  at the  change point .

Final speed :

This is the absolute value  of the speed  at point L defined as the final speed of the bobbin . the final speed must  never be  less then 400 m/ min.

Percentage of the final speed :

This is the percentage value of the  speed decrement  with respect to the  initial speed .

slip coefficient  (SC) :

This is used for  pre setting the package meterage .

production correction factor :

It used  to adjust  the no of kilograms produced by the  machine .  

VSS :-

The variable system allows  to control the tension when the bobbin is full and  when it is empty .

Advantages :

 better yarn quality  which presents a more  uniform uster  hairiness  and regularity . less part  bobbins , yarn breakage  at the end of the bobbin unwinding , wrap formation on winding drum  ribbon formation on the delivery package .incises the production.