Description:TECHNICAL FIELD
[001] The present invention relates to the field of textile manufacturing and, more specifically, to a roving condenser and a roving guide for improving separation and alignment of rovings in a SIRO yarn production system. The invention enhances the control and positioning of fiber strands during the drafting process, contributing to higher-quality yarn production with superior consistency and reduced imperfections.

BACKGROUND
[002] In textile manufacturing, the drafting process is a critical stage in which rovings are elongated and prepared for subsequent twisting into yarn. The uniformity and quality of the resulting yarn are heavily dependent on the precise control of the rovings during this process.

[003] Roving condensers are commonly used to guide and position the rovings as they pass through the drafting zone. Conventional roving condensers often feature open structures, which can result in unintended movement of the rovings. This misalignment can disrupt the drafting process and lead to variations in yarn count, negatively affecting the consistency and quality of the final product.

[004] Similarly, roving guides are used to provide support to the rovings between key points in the drafting system. Traditional roving guides are frequently short in length, offering limited support and control over the rovings. This limitation can cause slippage or breakage of the rovings during drafting, further contributing to inconsistencies in yarn production.

[005] In light of the aforementioned discussion, there is a clear need for more reliable systems and components to improve the stability and alignment of rovings during the drafting process, ensuring high-quality yarn with consistent properties.
SUMMARY
[006] The following presents a simplified summary of the disclosure in order to provide a basic understanding to the reader. This summary is not an extensive overview of the disclosure and it does not identify key/critical elements of the invention or delineate the scope of the invention. Its sole purpose is to present some concepts disclosed herein in a simplified form as a prelude to the more detailed description that is presented later.

[007] Exemplary embodiments of the present disclosure are directed towards roving guide for improving separation and alignment of rovings in SIRO yarn production system.

[008] An objective of the present disclosure is directed towards developing an improving SIRO core spinning process and apparatus for producing high-quality core-spun yarns with superior strength, smoothness, and reduced imperfections.

[009] Another objective of the present disclosure is directed towards enhancing fibre alignment and core filament integration, resulting in stronger and more uniform yarns with better core coverage.

[0010] Another objective of the present disclosure is directed towards utilizing cotton by-products effectively, reducing environmental impact, and improving productivity in spinning mills.

[0011] Another objective of the present disclosure is directed towards reducing yarn hairiness and imperfections through optimized drafting and twisting mechanisms.

[0012] Another objective of the present disclosure is directed towards increasing versatility in processing various fibre types and core filaments, including elastane, polyester, and other synthetic materials.

[0013] Another objective of the present disclosure is directed towards preventing slippage and breakage of rovings during the spinning process or SIRO yarn production.

[0014] Another objective of the present disclosure is directed towards preventing count variation in the final yarn caused by break draft bypass.

[0015] Another objective of the present disclosure is directed towards preventing roving breaks between the back roll and middle roll by providing nip-to-nip support to the roving.

[0016] Another objective of the present disclosure is directed towards providing a reliable and efficient apparatus for seamless core filament introduction and uniform twisting in the spinning process or yarm production.

[0017] According to an exemplary aspect, a roving guide for improving separation and alignment of rovings in a SIRO yarn production system, includes a roving guide positioned between a back drafting roller and a middle drafting roller of a drafting unit.

[0018] According to another exemplary aspect, the roving guide receives the twin rovings from a roving condenser and guides them into the drafting unit, wherein the roving condenser comprises twin apertures, positioned at the back drafting roller of a drafting unit.

[0019] According to another exemplary aspect, the roving guide comprises twin parallel grooves with an extended length configured to securely hold and guide the twin rovings while maintaining their separation.

[0020] According to another exemplary aspect, the extended length of the grooves provides continuous nip-to-nip support for the rovings from the nip of the back drafting roller to the feeding point of the middle drafting roller, thereby preventing slippage, entanglement, and misalignment, and facilitating precise feeding of the rovings into the drafting unit.

BRIEF DESCRIPTION OF THE DRAWINGS
[0021] In the following, numerous specific details are set forth to provide a thorough description of various embodiments. Certain embodiments may be practiced without these specific details or with some variations in detail. In some instances, certain features are described in less detail so as not to obscure other aspects. The level of detail associated with each of the elements or features should not be construed to qualify the novelty or importance of one feature over the others.

[0022] FIG. 1 is an example diagram depicting a schematic representation of a conventional guide used in the spinning process, according to prior art.

[0023] FIG. 2A and FIG.2B are example diagrams depicting schematic representation of a roving guide for improving separation and alignment of rovings in SIRO yarn production system, in accordance with one or more exemplary embodiments.

[0024] FIG. 3 is an example diagram 300 depicts a detailed view of roving guide, in accordance with one or more exemplary embodiments.

[0025] FIG. 4 is flowchart depicting an exemplary method for operating the roving guide to improve the separation and alignment of rovings in a SIRO yarn production system.

[0026] FIG. 5 is flowchart depicts an exemplary method for producing core-spun yarns to create a high-quality yarn in a SIRO yarn production system, in accordance with one or more exemplary embodiments.

[0027] FIG. 6 is flowchart depicts an exemplary method for improving separation and alignment of rovings in a SIRO yarn production system, in accordance with one or more exemplary embodiments.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS
[0028] It is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The present disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0029] The use of “including”, “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. Further, the use of terms “first”, “second”, and “third”, and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another.

[0030] Referring to FIG. 1, an example block diagram 100 depicts a schematic representation of a conventional guide used in the spinning process, according to prior art. The diagram 100 includes guide 102, roving 104. In conventional roving condensers, the guide 102 configured to align and support the roving during the drafting process. However, the conventional guide 102 is relatively small in length, leading to certain limitations in performance. Specifically, the drafted roving 104 receives minimal support between the back roll and front roll. This insufficient support results in issues such as slippage and breakage of the roving, which can adversely impact the efficiency and quality of the spinning process.

[0031] Referring to FIG. 2A and FIG.2B are example block diagrams 200a, 200b depicting schematic representation of a roving guide for improving separation and alignment of rovings in SIRO yarn production system, in accordance with one or more exemplary embodiments. The system 200a, 200b includes roving holders (not shown), a roving condenser 202 with twin aperture, a back drafting roller 204, rovings 205, a roving guide 206, a middle drafting roller 208 equipped with a top apron, a core filament 210, a filament guide roller 212, and a front drafting roller 214, a twisting unit (not shown), a winding unit 216. The drafting unit 203 comprises the back drafting roller 204, the middle drafting roller 208, and front drafting roller 214.

[0032] The roving holders(not shown) may be configured to securely hold the two rovings 205 at the top of the drafting unit 203, allowing them to feed freely into the drafting unit 203. The rovings 205 are directed through the twin aperture of the roving condenser 202, which is located at the back drafting roller 204. The roving condenser 202 with twin aperture aligns and condenses the rovings while maintaining slight separation between them. Following this, the rovings 205 pass through the roving guide 206, which is positioned between the back and middle drafting rollers. The roving guide 206 may be configured to facilitate precise feeding and prevents entanglement during the transition.

[0033] The rovings 205 then enter the middle drafting roller 208, which is equipped with a top apron to provide enhanced control and stabilization of the fibers/rovings during elongation and thinning. The drafting unit includes the top apron and a bottom apron extending from the middle roller to the front roller, offering additional stabilization of the fibers.

[0034] Simultaneously, the core filament 210 is introduced into the drafting unit 203 through the core filament guide roller 212. The core filament guide roller 212 positions the filament accurately between the two rovings, at the middle roller exit and the front roller entry point, facilitating smooth integration behind the front drafting roller 214. As the drafted rovings and core filament 210 exit the drafting unit 203, they are twisted together using the twisting unit. The twisting unit (not shown) imparts the necessary twist to the drafted rovings 205 and the core filament 210, ensuring proper integration of the core filament 210 into the yarn structure and forming a cohesive, uniform core-spun yarn with enhanced strength and reduced hairiness. In accordance to the exemplary embodiment of the present disclosure, the filament guide roller 212 positioned downstream of the drafting unit 203 is configured to align and incorporate a core filament 210 into the rovings 205.

[0035] Finally, the completed yarn is collected using the winding unit 216 may includes a spindle, a ring, and a traveler. The twisted core-spun yarn is wound onto bobbins or similar storage devices for subsequent processing.

[0036] Referring to FIG. 3, an example block diagram 300 depicts a detailed view of a roving guide, in accordance with one or more exemplary embodiments. The roving guide 206 may includes two parallel grooves to securely hold and guide twin rovings as they transition into the drafting unit 203(As shown in FIG.2A). These grooves facilitate precise alignment and maintain separation between the rovings, effectively preventing entanglement or misalignment during the feeding process. The two (twin) parallel grooves of the roving guide are made from a wear-resistant material to enhance durability and maintain precise alignment of the rovings during prolonged use. The extended length of the grooves in the roving guide is optimized to reduce fiber protrusion and enhance the uniformity of drafted rovings.

[0037] The roving guide 206 is strategically positioned between the back drafting roller 204 and the middle drafting roller 208(As shown in FIG.2A), facilaitating smooth and controlled feeding into the drafting unit 203 (As shown in FIG.2A). The guide provides continuous nip-to-nip support, extending from the nip of the back drafting roller 204 to the feeding point of the middle drafting roller 208. This configuration facilitates stability and accurate positioning of the rovings as they approach the middle drafting roller equipped with a top apron. The top apron of the middle drafting roller is made of a flexible material to provide smooth, even contact with the rovings, thus enhancing fiber control during the drafting process.

[0038] By maintaining alignment and tension, the roving guide 206 plays a critical role in facilitating uniformity and consistency during the fiber/rovings drafting process. Its integration with other components of the SIRO yarn production system, such as the roving condenser 202 with twin aperture and drafting rollers, enhances the overall precision and efficiency of the system. This arrangement provides the rovings are properly prepared for elongation and thinning, which are essential for producing high-quality core-spun yarns.

[0039] In accordance with an exemplary embodiment of the present disclosure, the roving guide 206 may be fixed to the system using a secure attachment mechanism, such as screws or bolts, which may facilitate its precise positioning and stability within the SIRO yarn production system. These fasteners may hold the guide firmly in place, allowing it to align and guide the rovings without shifting or loosening during operation. The guide may also be mounted on an adjustable bracket or frame to facilitate alignment and maintenance, enabling fine-tuning of its position relative to the drafting rollers. Other components of the system, such as the drafting rollers and filament guide roller, may generally be mounted on a rigid frame or housing structure to facilitate stability and precise alignment during operation. The drafting rollers, including the back, middle, and front rollers, may be supported by bearings and shafts, which may be fixed to the frame using mounting plates or brackets. The roving condenser 202 with twin aperture may be attached near the back drafting roller 204 using clamps or screws, ensuring it remains stationary while aligning the rovings. Similarly, the filament guide roller may be securely fixed, often with adjustable mounts, to allow accurate positioning of the core filament 210 relative to the drafted rovings 205. The twisting and winding units may be integrated into the system via a robust mounting mechanism, ensuring their alignment with the yarn path for seamless operation. Each component's attachment may be designed to provide durability and precision, minimizing vibration and maintaining alignment for consistent SIRO yarn production.

[0040] Referring to FIG. 4 is flowchart 400 depicting an exemplary method for operating the roving guide to improve the separation and alignment of rovings in a SIRO yarn production system. The method 400 may be carried out in the context of the details of FIG. 1, FIG. 2, and FIG. 3. However, the method 400 may also be carried out in any desired environment. Further, the aforementioned definitions may equally apply to the description below.

[0041] The method 400 commences at step 402, positioning the rovings and preparing a drafting unit for a SIRO yarn production process. Thereafter at step 404,directing the rovings from roving holders into a twin aperture roving condenser for alignment. Thereafter at step 406, guiding the aligned rovings into the roving guide positioned between the back drafting roller and the middle drafting roller. Thereafter at step 408, using twin grooves in the roving guide to securely hold the rovings. Thereafter at step 410, maintaining separation between the rovings to prevent entanglement during their transition through the drafting unit. Thereafter at step 412, providing continuous support to the rovings from the nip point of the back drafting roller to the feeding point of the middle drafting roller. Thereafter at step 414, preventing gaps or sagging in the rovings by maintaining continuous support. Thereafter at step 416, facilitating consistent tension on the rovings to prevent slippage, breakage, or uneven stretching. Thereafter at step 418, keeping the rovings properly aligned for precise feeding into the middle drafting roller. Thereafter at step 420, positioning the rovings accurately as they approach the middle drafting roller. Thereafter at step 422, stabilizing the rovings to prepare them for elongation and thinning during the drafting process. Thereafter at step 424, completing the operation of the roving guide once the rovings are fed into the middle drafting roller with proper tension and alignment, thereby facilitating continuous and uninterrupted drafting.

[0042] Referring to FIG. 5 is flowchart 500 depicts an exemplary method for producing core-spun yarns to create a high-quality yarn in a SIRO yarn production system, in accordance with one or more exemplary embodiments. The method 500 may be carried out in the context of the details of FIG. 1, FIG. 2, FIG. 3 and FIG.4. However, the method 500 may also be carried out in any desired environment. Further, the aforementioned definitions may equally apply to the description below.

[0043] The method 500 commences at step 502, preparing twin rovings using fiber material via a twin aperture roving condenser and selecting the core filament. The core filament may include but not limited to elastane filament. Thereafter at step 504, guiding the condensed rovings through the roving guide, ensuring alignment and parallel feeding into the drafting unit. Thereafter at step 506, drafting the rovings using a back drafting roller and a middle drafting roller equipped with a top apron, elongating and aligning the rovings while maintaining separation. Thereafter at step 508, introducing the core filament into the drafting unit via the filament guide roller, aligning it between the two drafted rovings. Thereafter at step 510, twisting and spinning the drafted rovings and the core filament together, centering the core filament and reducing surface fiber protrusions. Thereafter at step 508, winding the completed core spun yarn onto bobbins or collection devices.

[0044] Referring to FIG. 6 is flowchart 600 depicts an exemplary method for improving separation and alignment of rovings in a SIRO yarn production system, in accordance with one or more exemplary embodiments. The method 600 may be carried out in the context of the details of FIG. 1, FIG. 2, FIG. 3, FIG.4 and FIG.5. However, the method 600 may also be carried out in any desired environment. Further, the aforementioned definitions may equally apply to the description below.

[0045] The method 600 commences at step 602, positioning a roving guide between a back drafting roller and a middle drafting roller of a drafting unit, the roving guide receives twin rovings from a roving condenser and guides them into the drafting unit, the roving condenser comprises twin apertures positioned at the back drafting roller. Thereafter at step 604, guiding the twin rovings by the roving guide, which comprises twin parallel grooves with an extended length, the grooves securely holding and guiding the twin rovings while maintaining their separation. Thereafter at step 606, providing continuous nip-to-nip support for the rovings from the nip of the back drafting roller to the feeding point of the middle drafting roller through the extended length of the grooves, thereby preventing slippage, entanglement, and misalignment. Thereafter at step 608, facilitating precise feeding of the rovings into the drafting unit by maintaining the separation of the rovings, keeping them aligned, and preventing any gaps and sagging during the drafting process.

[0046] In accordance with exemplary embodiments of the present disclosure, the twin apertures of the roving condenser are configured to allow uniform feeding of rovings into the roving guide, minimizing fluctuations in tension.
[0047] In accordance with exemplary embodiments of the present disclosure, the twin parallel grooves of the roving guide are made from a wear-resistant material to enhance durability and maintain precise alignment of the rovings during prolonged use.

[0048] In accordance with exemplary embodiments of the present disclosure, the extended length of the grooves in the roving guide is optimized to reduce fiber protrusion and enhance the uniformity of drafted rovings.

[0049] In accordance with exemplary embodiments of the present disclosure, the middle drafting roller comprising top apron is made of a flexible material to provide smooth, even contact with the rovings, thus enhancing fiber control during the drafting process.

[0050] In accordance with exemplary embodiments of the present disclosure, the drafting unit further comprises a front drafting roller and the roving guide provides smooth feeding of rovings from the middle drafting roller to the front drafting roller.

[0051] In accordance with exemplary embodiments of the present disclosure, further comprising a filament guide roller positioned downstream of the drafting unit is configured to align and incorporate a core filament into the rovings.

[0052] In accordance with exemplary embodiments of the present disclosure, the filament guide roller introduces the core filament in alignment with the rovings to form a core-spun yarn when twisted downstream.

[0053] In accordance with exemplary embodiments of the present disclosure, further comprising a twisting unit downstream of the drafting unit, configured to impart a twist to the rovings, forming a stable yarn.

[0054] In accordance with exemplary embodiments of the present disclosure, further comprising a winding unit positioned to collect the processed yarn onto either bobbins or similar storage devices.

[0055] The use of “including”, “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. Further, the use of terms “first”, “second”, and “third”, and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another.

[0056] Reference throughout this specification to “one embodiment”, “an embodiment”, or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, appearances of the phrases “in one embodiment”, “in an embodiment” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

[0057] Although the present disclosure has been described in terms of certain preferred embodiments and illustrations thereof, other embodiments and modifications to preferred embodiments may be possible that are within the principles of the invention. The above descriptions and figures are therefore to be regarded as illustrative and not restrictive.

[0058] Thus, the scope of the present disclosure is defined by the appended claims and includes both combinations and sub-combinations of the various features described hereinabove as well as variations and modifications thereof, which would occur to persons skilled in the art upon reading the foregoing description.
, Claims:We Claim
1. A roving guide for improving separation and alignment of rovings in a SIRO yarn production system, comprising:

a roving guide positioned between a back drafting roller and a middle drafting roller of a drafting unit, whereby the roving guide receives the twin rovings from a roving condenser and guides them into the drafting unit, wherein the roving condenser comprises twin apertures, positioned at the back drafting roller of the drafting unit;

the roving guide comprises twin parallel grooves with an extended length configured to securely hold and guide the twin rovings while maintaining their separation, wherein the extended length of the grooves provides continuous nip-to-nip support for the rovings from the nip of the back drafting roller to the feeding point of the middle drafting roller, thereby preventing slippage, entanglement, and misalignment, and facilitating precise feeding of the rovings into the drafting unit.

2. The roving guide as claimed in 1, wherein the twin apertures of the roving condenser are configured to allow uniform feeding of rovings into the roving guide, minimizing fluctuations in tension.

3. The roving guide as claimed in claim 1, wherein the twin parallel grooves of the roving guide are made from a wear-resistant material to enhance durability and maintain precise alignment of the rovings during prolonged use.

4. The roving guide as claimed in claim 1, wherein the extended length of the grooves in the roving guide is optimized to reduce fiber protrusion and enhance the uniformity of drafted rovings.

5. The roving guide as claimed in claim 1,wherein the middle drafting roller comprising top apron is made of a flexible material to provide smooth, even contact with the rovings, thus enhancing fiber control during the drafting process.

6. The roving guide as claimed in claim 1, wherein the drafting unit further comprises a front drafting roller, and the roving guide provides smooth feeding of rovings from the middle drafting roller to the front drafting roller.

7. The roving guide as claimed in claim 1, further comprising a filament guide roller positioned downstream of the drafting unit is configured to align and incorporate a core filament into the rovings.

8. The roving guide as claimed in claim 7, wherein the filament guide roller introduces the core filament in alignment with the rovings to form a core-spun yarn when twisted downstream.

9. The roving guide as claimed in claim 1, further comprising a twisting unit downstream of the drafting unit is configured to impart a twist to the rovings, forming a stable yarn.

10. The roving guide as claimed in claim 1, further comprising a winding unit positioned to collect the processed yarn onto either bobbins or similar storage devices.

11. A method for improving separation and alignment of rovings in a SIRO yarn production system, comprising:
positioning a roving guide between a back drafting roller and a middle drafting roller of a drafting unit, the roving guide receives twin rovings from a roving condenser and guides them into the drafting unit, wherein the roving condenser comprises twin apertures positioned at the back drafting roller;

guiding the twin rovings by the roving guide, the roving guide comprises twin parallel grooves with an extended length, the grooves securely holding and guiding the twin rovings while maintaining their separation;

providing continuous nip-to-nip support for the rovings from the nip of the back drafting roller to the feeding point of the middle drafting roller through the extended length of the grooves, thereby preventing slippage, entanglement, and misalignment; and

facilitating precise feeding of the rovings into the drafting unit by maintaining the separation of the rovings, keeping them aligned, and preventing any gaps and sagging during the drafting process.