2.

Roving
2.6 Developments in roving frames
The speed frame is the machine that has gone least change. This can be realised from the fact that a spindle speed of 1,500 rpm as on
date as compared to 600 rpm in 1950s. Still there are certain changes that have been carried out for better production and quality like,
increase in the roving bobbin diameter from 4" to 7" and lift from 8" to 16", use of straight cone drum instead of hyperbolic cone drum for
better control over the roving tension etc. Now all closed (AC Type) flyers are used to overcome the problem of air drag on roving.
These flyers are aerodynamically balanced and are of light weight. The roving frames are equipped with auto doffing system that, apart
from avoiding manual handling, reduces doffing time.Even the Toyota claims to have auto doffing on FL100 roving frame in record time of
3½ minutes. Roving bobbins auto doffing and transportation, to the ring spinning through over head rails, becomes a standard feature of
the roving frame. Apart from above, some of the developments those are really significant will be discussed in subsequent sections.
Equal roving geometry for front and back row roving
Deposition of roving spindles in two rows leads to variation in roving twist and count in front and back row due to different level of twist
attained by roving in front and back row. This is due to change in roving path geometry . Modern speed frames have raised flyer top of
the back row as compared to the front row to maintain the roving delivery angle. Rieter F15/F35 roving frame, Zinser 668 roving frame,
Marzoli FTN roving frame and Lakshmi LFS 1660 speed frame incorporate this development in their machines.
Drive System
Main drive changed from loose/fast pulley system to centrifugal clutches.
To reduce noise and vibrations spur gears are replaced with helical gears with thrust bearings.(smooth & gradual engagement of
teeth)
For same speed reduction ratio helical gears are smaller in size – less pitch line velocity of gears.
Self-aligning ball bearings for top drafting rollers and use of needle bearings for bottom drafting rollers.

Replacement of bush bearings by ball bearing for creel rollers and gear shafts.

Latest trend is to use timing belts:

Greater flexibility in location of elements.

Power transmission efficiency as good as gears.

Less power consumption and noise compared to gears.

Simple drive system.

Less maintenance.

Individual motor drive

In multi-motor drive system, drafting rollers, flyers, bobbins and bobbin rail are driven directly by individual servomotors and are
synchronised throughout package build by the control system. The advantages of this system are like, no need of heavy counter weight
for bobbin rail balancing and differential gear, reduced maintenance, lower energy consumption, etc. All machine manufacturers
incorporate four-motor-drive system except Toyota that uses three servomotors on FL100 roving frame. One motor for drafting system
and flyer while one motor each for bobbin drive and bobbin rail. Figure 1 shows the schematic of the multi-motor drive system.
 Figure 1 : Schematic of the multi-motor drive system.
Microprocessor controlled Building Mechanism
Technological parameters like length of roving in first layer, taper angle, no of layers, count, type fibers- are fed to the control
panel.

Bobbin speed and Bobbin rail position are sensed by electronic sensors.

Tapering, rail movement etc. are controlled by Computer.

Operator is lead by operating menus and has all important information all the time.

Adjustments can be stored, and transferred to other machines.

Roving tension sensors

Roving tension sensors measure and control the roving tension (constant) through out the bobbin build. These tension sensors do not
actually contact the roving while measuring the tension. The tension is measured at periodic intervals and the required change in tension
is actuated by changing the bobbin speed through servomotor. Rieter F15/F35 roving frame, Zinser 668 roving frame, Marzoli FTN roving
frame, Lakshmi LFS 1660 speed frame and Toyota FL100 roving frame have incorporated roving tension sensor on their machines. Figure
2 shows the roving tension sensor used in Rieter roving frame.
 Figure 2 : Roving Tension sensor (Rieter F15/F35 roving frame)
Bobbins doffing
This is an important area where automation should be done. Nowadays manual doffing is costly, time consuming and ergonomically
unsatisfactory operation that has a significance influence on efficiency. Development of the fully automated roving frame has resulted in a
significant reduction in doffing time. Separate actuation of bobbin rail and doffer rail is the basis for the shortest doffing time compared
with manual doffing.

Figure 3 : Bobbin automatic doffing (Zinser RoWeMat)

The built-in automatic doffer is integrated in the machine in such an ingenious way that it does not interfere with production. At the same
time all components are easily accessible before and after the doffing process. Storing the full bobbins and empty tubes also takes place
in the roving frame. The results are short doffing times and higher efficiency.
Doffing and re-starting are executed automatically. And this is done completely without personnel. In this process, the roving bobbins are
stored in the machine, while production can continue without any delay. Development of the fully automated F 35 roving frame has
resulted in a significant reduction in doffing time. Separate actuation of bobbin rail and doffer rail is the basis for the shortest doffing time
compared with other products. Both processes are controlled by frequency converters and can therefore be performed synchronously and
independently of each other. While the bobbin rail with the full bobbins is lowered and placed on the slide, the doffer rail leaves its idle
position and is lowered slowly. The slide with the bobbin rail moves forward out of the machine.
The ability to control the sequences of motion separately enables the doffing process to be shortened considerably and doffing times of
less than 2 minutes are realistic. Doffing time is independent of machine length, i.e. minimum doffing times are also applicable to long
machines. The operation of the doffer is also assured during maintenance and other transport system downtimes. The doffer rail with the
full bobbins can be lowered to a convenient working height so that the bobbins can be removed manually.
The fully automated Rieter F 35 roving frame performs doffing in less than 2 minutes. This has been made possible by separate actuation
of bobbin rail and doffer rail by two independent frequency converters. The doffing sequence of the doffing is illustrated in Figure 4.

Click on Figure to run the animation

Figure 4 : Doffing sequence (Rieter Roving frame)

1. – The bobbin rail (1) moves out and at the same time the footboard is set up. – The doffer beam with the empty tubes is
lowered between the full bobbins (2).; 2. – The empty bobbin pegs of the doffer beam grasp the full bobbins. (All the
bobbin pegs are now occupied). – The doffer beam moves up to reversing position.; 3. – The conveyor belt in the doffer
beam moves into intermediate position.; 4. – The doffer beam puts the empty tubes onto the spindles.; 5. – The doffer
beam moves into top position with the full bobbins. – The slide moves in and the footboard is lowered at the same time. –
The safety zone is free again.; 6. – The bobbin rail (1) is raised to spinning start-up position. – The full bobbins (2) are
transported to the transfer station. – The roving frame starts up automatically
Bobbins transport :
Transporting individual roving bobbins manually from the roving frame to the ring spinning machine is labor-intensive and often results in
damage to the roving.60 % wages cost can be attributed to cost of transport due to manual transport.In case of automatic transport of
bobbins improves the high degree of flexibility, substantial increase in quality and productivity, and reduced labor costs.The result in well
organized, space-saving production processes and ready access to the machines.
Manual transport of roving bobbins with carriages not only is work-intensive, but the roving may also be accidentally damaged by the
operating staff. For the outer roving layer is very sensible, particularly as the roving only has a protective twist. Damage in the roving is
transmitted through the entire process chain and affects the quality of your yarn. It is also known that roving bobbin carriages may even
be forgotten or mixed up in the mill. A mistake that might not be noticed until in the finished fabric - with severe consequences. In
contrast, a transport system automatically transports any roving bobbin to the right position.
The advantages are

Roving bobbins are not touched, the bobbin surface is not damaged

No intermediate storage which might result in damage, soiling, or ageing of the roving

No confusions between different roving bobbins ensuring the application of the “first-in, first-out” principle

Clearly structured material flow, speeding-up processes

Equalising of work processes and smoothing of production peaks

Stop motions
In case of roving or sliver break machine should stop immediately in order to avoid production loss and creation of faults in the roving.
Sliver stop motion:
 By light emitter and photocell

Located between the last transport roller of the creel and the drafting system

m/c should stop , in case of sliver break

Roving stop motion:

(a) Light beams fall on flyer tops

In case of a roving break , broken roving ends whirl around (hood)

Interrupts light beam

m/c stops

Figure 5 : Roving stop motion

(b) Luwa Pneumastop

Figure 6 : Luwa Pneumastop Mechanism

Pneumatic suction system in delivery of drafting system

- To avoid series of roving breaks

Suction system draws the drafted strand into a large collector duct, extended in full m/c length

Fibres pass through capacitor

- Two comb electrodes

Change in capacitance generates a signal to stop the m/c.

Other Possible places for Automation

Can changing

Automatic can mechanism in roving frame will bring at least partly automated machine

Piecing the broken slivers

Automatic piecing of broken sliver will improve the production speed and quality of piecing.

Cleaning

Cleaning has already been automated to sufficient level by means of cleaning aprons, clearer rollers and suction systems.

Machine monitoring

Monitoring equipments are now essential in textile mills especially in the roving frames. Sufficient work has been done to improve
quality and reduce burden on personnel.

Production monitoring

With this automation, the machine will run day and night without interruptions.

Quality monitoring

Quality of the roving is checked machine itself by monitoring it and helps to improve the product realization.

Maintenance and servicing

Many works have been done in this area by way of central lubrication, low maintenance design and so on.