The spinning process flow of cotton-type acrylic, polyester and wool A/T/W 80/10/10 18tex was determined, and the factors affecting the roll quality of the blowroom cotton process were analyzed. Through reasonable configuration of the blowroom cotton process, feasible measures were taken Measures have been taken to solve the problems of A/T/W 80/10/10 18 tex blended yarn sticking, winding, traffic jams and uneven evenness in the opening and cleaning process.
0. Preface
In recent years, with the substantial improvement of people’s living standards, people’s requirements for clothing and textile products have become higher and higher. Some common varieties have been gradually eliminated in the fierce market competition. The development of blended yarns made of three raw materials, nitrile, polyester and wool, will play a positive role in upgrading products, adapting to the market, and improving corporate efficiency.
my country is rich in combed noil and short wool resources, and acrylic fiber has wool-like characteristics. Using cotton spinning equipment to develop acrylic-polyester-wool blended yarn has the advantages of short process, low cost, high efficiency, and good wool-like feel. However, when developing polyester-wool blended yarn on cotton spinning equipment, active and feasible measures must be taken in the blowroom process to ensure the smooth progress of subsequent processes.
1. Analysis of raw material characteristics
1.1 Raw material properties
(1) Polyester staple fiber (1.65 dtex×38 mm) has the characteristics of good hygroscopicity and easy coloring, and can be made into polyester rolls on polyester staple fiber opening and cleaning equipment.
(2) Cotton-type acrylic (1.65 dtex × 38mm) looks and feels like wool. The yarn blended with wool is made into wool fabrics, which has the characteristics of low cost and good wool texture. Because 1.65 dtex × 38mm cotton-type acrylic fiber has the following characteristics, which affects the spinnability: less impurities, more hard filaments, and more bundles; low moisture regain, easy to generate static electricity during processing, winding the rollers in the spinning equipment and beaters; the cohesion force and frictional resistance between fibers are large, and the mechanical channel requirements are high during the spinning process; the elasticity is good, but it is relatively fluffy and easy to stick to each other.
(3) Short wool tops have better wool feel and shorter length, and can be blended with polyester and nitrile in the process after blow cleaning.
1.2 Blended yarn process
Polyester staple fiber: A002 disc cotton picking machine-A035 cotton blending machine-A036 type porcupine cotton opener-A092 double cotton box cotton feeder-A076 type roll forming machine-A186 type carding machine
Cotton type acrylic fiber: A002 disc cotton picking machine – A035 cotton blending machine – A036 porcupine cotton opener – A092 double cotton box cotton feeder – A076 rolling machine – A186 carding machine (add top)
Polyester sliver and woolen nitrile sliver: A272 draw frame – A454 roving frame – FA502 spinning frame – 1332M winding machine
2. Problems existing in the spinning process
Acrylic fiber is easy to wrap around rollers and beaters when it is rolled in the opening and cleaning process. It is easy to block pipes, stick to the roll, and have poor roll uniformity, which will have the following effects on production:
(1) Acrylic fiber blocks the pipes of the single blowroom machine and wraps around the rollers and beaters of the single blowroom machine, affecting production and efficiency and causing supply disruption.
(2) It is difficult to unwind the acrylic fiber from the coil to the carding process, and the adhesion is serious, which directly affects the uneven weight of the card sliver and the uneven weight of the finished yarn. It also increases the backlash during the production process and easily damages the card clothing.
(3) The uniformity of acrylic fiber rolls is poor, resulting in uneven yarn weight.
3. Processes and measures adopted in the cotton blowing and cleaning process
3.1 Process principles
In order to prevent entanglement and traffic jams, it is advisable to adopt the principle of “loosing more and beating less, combing instead of beating, recycling more, removing less, and mixing thoroughly”. details as follows:
(1) Beater mode: Use a full-comb needle roller with soft blow and fine combing effect to replace the porcupine beater.
(2) Beater speed: full comb needle roller simple speed 500 r/min ~ 550 r/min, roll beater speed 750 r/min ~ 800 r/min.
(3) The fan speed is changed from 1300 r/min to 1500 r/min.
(4) The spacing should be small, and the dust rod should be installed backwards to increase air recovery and seal off individual trash areas to ensure smooth fiber transportation; the distance between the dust rod and the beater should be increased by 1.5 times to reduce the Excessive rubbing of fibers produces bundles; adjusting the distance between the cotton feeding roller and the beater to 12mm, and adjusting the distance between the cotton stripping knife and the beater to 1mm can solve the problem of fiber entanglement with the combing needle and beater.
(5) Regularly clean the pipes, especially the elbows of the pipes, and remove burrs and cotton wax every three days to effectively solve the problem of fiber clogging.
3.2 Prevent sticking
To prevent roll sticking, you can take the following measures:
(1) The rolling machine is equipped with a roving clamping device. Use 6 to 8 rovings as separate layers to prevent adhesion when carding and unwinding.
(2) Heating and shaping. Use electric heating wires to heat the second and third pressing rollers, so that the surface temperature of the two rollers can be controlled at about 100°C, so that the fiber layer can be temporarily heat-set, reduce the fluffy phenomenon, and make the roll well-formed and less likely to stick.
(3) Acrylic fiber rolls are available in fixed weight and short length. The acrylic roll adopts the process of slightly heavier weight and shorter length. The fixed-length gear is adjusted from the original 33 teeth to 28 teeth. The weight is guaranteed to be around 13kg. This will help improve the fiber layer structure.Increase the cohesion between fibers to reduce sticking.
(4) Increase the pressure of the pressing roller to make the cotton layer structure tighter and less likely to stick to the layer.
(5) Increase the ratio of condensed cotton in the upper and lower dust cages. A single upper dust cage is used to condense fibers, and the air ducts on the left and right sides of the lower dust cage are closed to close the lower dust cage for air suction, thereby reducing the amount of condensed fibers in the lower dust cage and keeping the ratio of the amount of condensed fibers in the upper and lower dust cages at 7: Around 3, this has a significant effect on preventing sticking.
3.3 Strengthen uniformity control
In order to control the uniformity of the cotton roll, the following measures can be taken:
(1) In order to reduce the violent tumbling of acrylic raw materials in the cotton box to form fiber clumps, the front and rear cotton storage boxes of the A092 double cotton box feeder need to reduce the inventory. In order to prevent the return roller from returning to flower, the V-shaped curtain is separated up and down. The distance is 3mm-5mm longer than when spinning cotton, and the height of cotton storage is reduced.
(2) Carry out quantitative supply work. In order to ensure a uniform and stable output fiber layer, the cotton box operation rate is controlled at 85%-90%, which reduces the fluctuation of cotton output caused by the stoppage of the cotton feeder parts and better controls the uniformity of the cotton lap.
(3) Clean the pipes regularly. Due to the large friction factor between acrylic fiber and metal, it is easy to scratch the channel wall, causing the fiber to stick, increasing the transportation resistance and making the cotton flow sluggish. Regular cleaning of the pipeline will solve this problem.
(4) Dulcimer crosses chromium. Since the friction between the acrylic fiber and the dulcimer is large and it is difficult for the dulcimer to move forward smoothly, it is more beneficial to control the uneven weight of the roll by chromating the dulcimer.
(5) Frequently check the function of the balance adjustment device.
4 Conclusion
(1) After taking corresponding process and technical measures, traffic jams rarely occur in the cotton blowing and cleaning process. The number of acrylic rolls per head per shift is up to 100, and the production efficiency is high. Each head can produce 40-50 more acrylic rolls than before. Only rolls ensure the stability of supply and production.
(2) The phenomenon of roll stickiness is basically eliminated. The acrylic fiber roll to carding and unwinding is relatively smooth, with less backlash, and the operation is normal. There is no phenomenon of the card clothing being damaged due to roll stickiness.
(3) The quality is relatively stable, and the uniformity of the acrylic fiber rolls tested in each shift can be controlled within the index range. For this reason, the uneven weight of A/T/W 80/10/10 18tex blended yarn is also more stable, and the yarn quality meets the standard requirements.
(4) A/T/W 80/10/10 18 tex blended yarn has better economic benefits after mass production, and the wage per ton of yarn is 3,000 yuan higher than that of T/C 18 tex.
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