Sunday 13 November 2016

Brief study of a card machine...

Second department of a short staple spinning mill is carding. Its importance could be judged from this famous quote in spinning, “Carding is heart of spinning”. It is a must needed department for every short staple spinning technique.
Objectives of carding actions are;
  1. Individualization of fibers
  2.  Orientation of fibers
  3.  Elimination of remaining impurities
  4.  Elimination of dust
  5.  Disentanglement of neps
  6.  Elimination of short fibers
  7.  Fiber blending
  8.  Sliver formation

Lakshmi Card Machine:



Three different models of carding machines are manufactured by Lakshmi;
1.         Lakshmi Card LC-636
2.         Lakshmi Card LC-363
3.         Lakshmi Card LC-333
All three models have almost same parts and has same type of working. LC-636 is a little bit different from other two, because of its more working width and high production but all parts and their working is same.
Following are the parts and their working of Lakshmi carding machine;
Chute fan: It sucks material from blow room into the chute.
ARGUS: Next to the fan an ARGUS is placed to detect any flame producing content in material.
Chute: It is just like a pipe but in rectangular shape to carry material from blow room department to carding department.
Material receiver box: A box is available on card machine in which material is fed by chute.
Chute feed roller: A feed roller is used under material receiver box to evenly feed the material.
Opening roller: A revolving beater opens the material before carding operations.
Lap roller: It receives material from opening roller and make an even sheet of material called lap.
Lap plate: It just guide the lap to feeding zone of card.
Feed plate: Feed plate is placed above the feed roller of machine for even feeding and guidance purposes.
Feed roller: Feed the material to taker-in section of card machine.
Taker-in section: Three taker-in rollers are available in this section. Each roller has thick saw tooth clothing on it. Density of clothing increases gradually from 1st taker-in to 3rd taker-in. Trash is collected under first taker-in. Taker-in prepares the material for main carding action between cylinders and flats.
Segment bars: Each taker-in has a segment bar on it for material opening and removal of trash particles.
Cylinder: It is responsible for the main carding action and is biggest in size. High density needle type clothing is available on cylinder to open the material to individual fiber level. One lay of fibers took three rounds on cylinder.
Revolving flats: Flats are strips of needle type clothing, moves above cylinder in opposite direction of cylinder to disentangle neps and orientation of fibers.
Cleaning brush: On top of the 3rd taker-in above flats a brush is used to clean the flats from back side. It is also called back cleaning brush.
Fly comb: It is placed on back side of revolving flats to extract out fly waste.
Bolts for gauge setting: Nine bolts; three above revolving flats and three under revolving flats are used to adjust flat gauge with cylinder.
Back top plate: Also called back top set, it is on back side of cylinder just in start of revolving flats to guide fibers.
Back stationary flats: Three sets of stationary flats are on back side of cylinder to aid main carding action.
Knife: Two knives are used in between back stationary flats to extract out trash particles.
Back bottom plate: It is at the bottom of cylinder in back side and guide the fibers at bottom.
Front bottom plate: It is at the bottom of cylinder on its front side to guide fibers.
Front stationary flats: Two sets of stationary flats are in front side of cylinder to aid carding action.
Knife: Two knives are used between front stationary flats to remove impurities and foreign matter.
Front top plate: Also called front top set, is on front side of cylinder at top.
Control stick: A control stick is attached near to front stationary flats to control amount of doffing material.
Doffer: Doffer is another roller with thick clothing on it to doff the material from cylinder.
Suction between cylinder and doffer: A pipe is used in between cylinder and doffer to suck dust and fly in this section.
Front cleaning brush: It is on the front side of flats to remove short fibers from revolving flats.
Suction between doffer and stripper roll: Another suction pipe is used to suck dust and fly in between doffer and stripper roller.
Stripper roll: Also called redirecting roller (RD roller), is to forward or redirect doffed fragile web to crush rollers.
Transparent plate: It is under the stripper roller to collect any trash particles falling down from the formed fragile web.
Crush rollers: Two rollers with spiral grooves in them are available in front of stripper roll to crush leave particles in the web.
Trumpet: It is just a hole to form slivers from wide fragile web. It guides web fibers to form a sliver.
Calendar rollers: Sliver passes through calendar rollers and is condensed by pressing.
Sliver guide: A hook type sliver guide is used to guide the sliver to coiler.
Coiler calendar rollers: These are above the coiler to condense the sliver and fed it to coiler.
Coiler: It is just like a round plate with hole on one side to pass the sliver from it. It revolves above sliver can to make coils of material in can.
Can: It is a long round box with spring inside it to carry the sliver from card machine to next draw frame.
Automatic can changer: It uses pneumatic pressure to hange the full can with empty can automatically.
      

Specifications:

Major specifications of Lakshmi Card Machines are;

Attribute
LC-333
LC-363
LC-636
Manufacturer
LAKSHMI
LAKSHMI
LAKSHMI
Model
2011
2013
2014
Type
LA 7/6
LA 7/6
LA 7/7
Max. Production
(at 100% efficiency)
100kg/hr
100kg/hr
200kg/hr
Running Production
(at 88% efficiency)
54kg/hr
54kg/hr
96kg/hr
Weight of feed
500g/m
500g/m
800g/m
No. of taker-in
3
3
1
Cylinder diameter
1270mm
1270mm
1016mm
Working width
1 meter
1 meter
1.5 meter
Sliver count range
0.08 – 0.18Ne
0.08 – 0.18Ne
0.09 – 0.25Ne
Sliver output grains
75gr/yd
75gr/yd
100gr/yd
Sliver output grains Range
77 ± 2
77 ± 2
100 ± 5
Delivery speed
200m/min
200m/min
235m/min
Total no. of flats
82
97
101
Back stationary flats
08
08
07
Front stationary flats
05
05
05
Revolving flats
27
33
33
Mote knives
5
5
6
Efficiency
88%
88%
92%
Total Waste
2 – 10%
2 – 10%
2 – 6%
Speed of rollers
Opening roller
1175rpm
Feed roller
5-6rpm
Doffer
200m/min
Taker-in
1st
2nd
3rd
984rpm
1100rpm
1450rpm
Cylinder
515rpm
Calendar roller
200m/min
Delivery speed
200m/min
Flats speed
160m/min
Drafts
Total draft
100
Tension draft
1.01
Sliver draft
1.05
Web draft
1.5
Draft between calendar roller and coiler
1.2
Power Input and Connected Loads
Motor
Power (KW)
Motor speed (RPM)
Main motor
9.30
1465
Doffer motor
1.80
1440
Web doffing motor
0.55
552
Chute fan motor
0.75
1250
Chute feed motor
0.2
15
Feed motor
0.37
11
Brush motor
0.25
2780
Taker-in motor
1.80
1400
Flats and cleaning motor
0.014
80
Coiler drive motor
1.50
1420
Can changer
0.25
16
Control circuit
0.50
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Total power
17.284KW

Lakshmi Card Machine Operational Diagram: