FIELD OF THE INVENTION:
The present invention relates to a system for reducing the rejection of low content
bobbins, and more particularly to a system and method to reduce rejection of low
content bobbins at the Link-Coner in the manufacturing of yarn.
BACKGROUND OF THE INVENTION:
Spinning is a part of the textile manufacturing process, where cotton fibers are
converted into yarn, then fabrics, which undergo finishing processes, such as
bleaching to become textiles. The textiles are then fabricated into clothes or other
products. There are different industrial processes available to spin yarn, and also
manual processes such as those used by a handicraft community who use hand
spinning techniques. Spinning is twisting together of drawn out strands of fibers to
form yarn, though it is colloquially used to describe the process of drawing out,
inserting the twist, and winding onto bobbins.
The process of manufacturing yarn employs a typical step of winding the yarn in the
bobbins and then into finished yams in cones. During this process bobbins are
subjected to air blow by a blower for removing the yarn completely from the bobbins.
However, it has been noticed that the conventional blowing processes result in
incomplete removal of the yarn and few bobbins are left rotating in CBF path,
resulting in generation of hard waste and high idle time of the ring frame machine.
There have been many processes described in the prior art to find an end of a yarn in a
bobbin. A patent numbered US 4858836 describes a device for finding an end of a
yarn whereby an end of a yarn connecting to a layer of the yarn on a bobbin is found
and is inserted into a center hole of a bobbin. The device includes an air flow
controlling plate located near an outer periphery of a layer of a yam on a spinning
bobbin and a compressed air injection nozzle located in a gap between the air flow
controlling plate and the yarn layer of the I . spinning bobbin.
The device also comprises an air flow controlling plate located near the outer
periphery of the layer of yarn on the spinning bobbin and extending in a direction of
the axis of the spinning bobbin, an air injection nozzle located in a gap between the
air flow controlling plate and the yarn layer on the spinning bobbin, a suction pipe for
sucking an end of the yarn to provide a path of yarn extending between the bobbin and
the suction pipe and a sensor for detecting whether the cut yarn is inserted in the
center hole of the bobbin.
Though the above mentioned patent provides a device for detecting the yarn end for
various types of bobbins and introducing an end of the yarn on a bobbin in to a center
hole, solving the problem of conventional yarn end finding device where an end of a
yarn is occasionally not inserted to a predetermined position, in a step of inserting a
yarn into a center hole of the bobbin, the device involves various sub systems like air
injection nozzle, air flow controller plate, a suction pipe, and a sensor making the
device complex in structure.
Another prior art US 3334740 describes a bobbin handling system which relates to the
handling of bobbins, quills or the like which have had yarn disposed therefrom. The
system involves a conveyer, a photoelectric detector, two ejecting means to eject the
bobbins with little yarn and an air nozzle supplied with air under pressure. When the
bobbins are taken by the conveyer, the photoelectric detector detects the bobbins with
little yarn and eliminate from the conveyer.
Although the system described in the above mentioned prior art is an effective system
for eliminating the unnecessary use of manual labour in order to expedite the handling
of bobbins and at the same time reduce operating cost, the function of the system is to
detect and eject bobbins with a little yarn on them from those bobbins with lot of yarn
on them. The ejected bobbins with little yarn are stripped and the yarn is sold as waste.
Hence, the system does not solve the problem of reducing the wastage of yarn.
Therefore, there exists a need to introduce a system which is simple in structure and
minimizes the waste generated from rejection of low content bobbins in yarn
manufacturing industry, and hence reduce the machine idle time.
SUMMARY OF THE INVENTION:
Before the present systems and methods are described, it is to be understood that this
invention is not limited to the particular apparatus and methodologies described, as
there can be multiple possible embodiments of the present invention which are not
expressly illustrated in the present disclosure. It is also to be understood that the
terminology used in the description is for the purpose of describing the particular
versions or embodiments only, and is not intended to limit the scope of the present
invention which will be limited only by the appended claims.
The present invention is directed to a system for reducing rejection of low content
bobbins comprising: (a) a blowing tube placed vertically along the length of the bobbin;
(b) an air blower coupled with the blowing tube.
Preferably the blowing tube is made of copper material.
In an embodiment of the invention, the blowing tube blowing tube has an angle of
blowing within a range of 65" - 75 O.
Preferably the blowing tube is placed at an angle of 70 O and at a height of 8 mm to the
bobbin.
In another preferred embodiment, the blowing tube blows the yarn vertically along the
length of the bobbin.
Other preferences are described below.
The blowing tube has a thickness of 0.2mm, length of 1 OOmm, an internal diameter of
6mm, and an orifice size of 0.5mm.
The present invention enables the practitioner to increase productivity of yarn by
eliminating the idle time of the ring frame machine. The elimination resulted in the
productivity increase of 1738.8 kglmonth. Also, it reduces the waste generated by the
rejection of low content bobbins.
Further, the present invention discloses a method for reducing rejection of low content
bobbins, in a yam manufacturing process, comprising the steps:
attenuating rovings at a ring frame machine in the yarn manufacturing process,
where the rovings are spun and wound to form yarn bobbins;
feeding the yarn bobbins to a link coner CBF from the ring frame machine to
inspect the yarn bobbins;
blowing the yarn bobbins using a blowing tube inclined vertically at an angle
of blowing to the yarn bobbins, in a searcher at the link CBF, to find yarn end; and
feeding the checked bobbins to winding machine from the ring frame machine,
where the yarn bobbins are spun and wound to form yarn cones.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS:
The foregoing summary, as well as the following detailed description of preferred
embodiments, is better understood when read in conjunction with the appended
drawings. For the purpose of illustrating the invention, there is shown in the drawings
example constructions of the invention; however, the invention is not limited to the
specific methods and apparatus disclosed in the drawings:
Figure 1 illustrates front view of copper tube used in the link CBF in accordance with
an embodiment of the invention;
Figure 2 illustrates the copper tube placed vertically along the length of bobbin in the
Link Coner CBF in accordance with an embodiment of the invention; and
Figure 3 illustrates a method for reducing rejection of low content bobbins, in a yarn
making process, in accordance with an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION:
This patent describes the subject matter for patenting with specificity to meet statutory
0
requirements. However, the description itself is not intended to limit the scope of this
patent. The principles described herein may be embodied in many different forms.
Illustrative embodiments of the invention now will be described more fully hereinafter
with reference to the accompanying drawings, in which some, but not all embodiments
of the invention are shown. Indeed, the invention may be embodied in many different
forms and should not be construed as limited to the embodiments set forth herein;
rather, these embodiments are provided so that this disclosure will satisfy applicable
legal requirements. Like numbers refer to like elements throughout.
The present invention discloses a system for reducing the rejection of low content
bobbins in textile yarn manufacturing process by searching the yarn end of the low
content bobbin by deploying a copper tube to blow yarn vertically along the length of
the bobbin. The copper tube blows the yarn vertically along the length of bobbin at a
predetermined angle and a height leading to opening the yarn till the last layer for
searching the yarn end.
During the process of manufacturing yarn, the bobbins from ring frame machine are
passed through link CBF for searching the yarn end. At the link CBF, an air blow
searcher is used to search the end of the yarn wound over a bobbin, in order to reject
an empty bobbin to the ring frame and a checked bobbin, which is a full wound
bobbin, to winding. Thereafter, the ring frame machine feeds the bobbins, containing
various contents of yarn winded on them, to link coner winding for winding the yarn
into a cone. The major setback in this process is that the low content bobbins are
rejected because of the inability of the searcher to locate the yarn end. The major
reason for this rejection is the limitation in yarn blowing by the searcher blow pipe.
This is because the searcher blower is designed to work upto a certain height of bobbin
and hence, couldn't locate the yam end of the low content bobbins. Resultantly, the
low content bobbins rotate in the link CBF section and disrupt the input and output of
the ring frame machine resulting in high idle time of the machine.
Therefore, to reduce the idle time of the winding machine by reducing the rejection of
low content bobbins, the present invention discloses a system that deploys a copper
tube in searcher of the link CBF to blow yarn vertically along the length of the bobbin
leading to opening the bobbin till last layer of yarn and search the yarn end. Figure 1
illustrates the front view of the copper tube (1) used in the searcher of the link CBF, in
accordance with an embodiment of the present invention. This blowing tube (1) made
of copper maintains an angle of blowing to the bobbin to blow air vertically and
possesses a rust proof nature due to its copper material. Preferred dimensions of the
copper tube (1) are shown in the figure 1. The copper tube (1) is able to withhold the
angle of blowing for prolong time with, a preferable diameter (orifice size) of 0.5mm,
preferably to maintain the air blowing velocity. Further, the copper tube (1) preferably,
has an internal diameter of 6mm.
Figure 2 illustrates copper tube placed vertically along the length of bobbin in the Link
Coner CBF, in accordance with an embodiment of the present invention. In a preferred
embodiment of the present invention, a copper tube (1) is deployed in searcher (3) of
the link CBF (4) vertically along the length of the bobbin (2) at an angle to the bobbin
to blow yarn so that it can search the end of the yarn in low content bobbins as well. In
an embodiment, the angle of blowing at which the copper tube (1) is placed in the
searcher with respect to the bobbin may lie within the range of 65'- 75'. In a preferred
embodiment, the copper tube (1) is placed at an angle of 70°and at a height of 8 mm to
the bobbins (2). The angle of the copper tube (1) blowing the air is crucial and is to be
maintained precisely .The copper tube (1) blows air over the bobbin which leads to
opening of the bobbin (2) till last layer and enables the searcher (3) for locating the
yarn end. Locating the yarn end of the low content bobbin eliminates the rejection of
low content bobbins and hence, the low content bobbins doesn't rotate in the link CBF
(4) leading to no blockage of the ring frame machine (5).
Figure 3 illustrates a method for reducing rejection of low content bobbins in link CBF
in a link frame machine for a yarn manufacturing process, in accordance with an
embodiment of the present invention. The method shows the steps in a yarn
manufacturing process, showing the steps after ring frame machine. Before ring frame
machine (5), during the yarn making process, carding is carried out after blow room
which involves process of opening and cleaning of cotton, after which slivering
(doubling and drafting) is done in a draw frame to form uniform sliver. After this a lap
is prepared on lap former machine which is used on comber to remove the short fibers
and neps from the material. This material (sliver) is again processed on draw frame
(doubling & drafting) which is used to form rovings of yarn on speed frame.
Thereafter (in the Fig. 3) at step 302, attenuation of the rovings at the ring frame
machine (5) is done, where a roving is spun and wound around a rotating spindle to
form a yarn bobbin (2). Further, at step 304, the yarn bobbins (2) are fed to link coner
CBF (4), where the yam bobbins (2) are inspected. Furthermore, at step 306, at link
CBF (4), a searcher (3) is deployed with a copper tube (1) which is vertically inclined
at an angle of blowing to the each incoming bobbin (2), in order to search the yarn end
by blowing air through the yarn vertically along the length of the bobbin (2) leading to
opening the bobbin (2) till the last layer of yarn. Advantageously, the copper tube (1)
helps to blow the yarn till the last layer and successfully finds the end of the yarn.
Now, the low content bobbins (2) do not rotate in the CBF (4) path and hence the idle
time of the machine (5) is reduced. Hence, using a copper tube (2) in the link CBF (4)
reduces the rejection of the low content bobbins (2).
a In an embodiment of the present invention, the copper tube (I) maintains an angle of
blowing with respect to the bobbins (2) within a range of 65'- 75'. In a preferred
embodiment, the copper tube (1) is inclined at an angle of 70' and at a height of 8mm
with respect to the bobbins (2).
Furthermore, at step 308, after searching the yarn end, the checked bobbins (2)
containing any amount of yarn over it, whether full or bottom bobbin, are fed to the
winding machine. Here, the yarn bobbins (2) are further spun and wound into a yarn
cone. This system greatly reduces the idle time of the ring frame machine (5) and
rejection of low content bobbins (2) and increases the productivity of the yarn
manufacturing process.
After the step 308, where the checked yarn bobbins (2) are spun and wound into yarn
cones, it is further checked, at step 3 10, whether the bobbin (2) is finished completely
in winding them into cones. If the yarn bobbin (2) is completely wound into a yarn
cone, then the yarn manufacturing process ends here. On the other hand, if the bobbin
(2) is not completely wound into a yarn cone, at step 312, the bobbin (2) is fed again
to the CBF preparation. From here the process goes back to the step 306, where the
bobbin (2) is again air blown by the searcher (3) using the copper tube to find the yarn
end. Thereafter, the process repeats till the yarn bobbin (2) is completely spun and
wound into a yarn cone.
Advantageously, the present invention results in the reduction of hard waste generated
in yarn manufacturing and also minimize the idle time of the ring frame machine (5).
Further, the present invention can be implemented in all fine count 23 Link coner
machines and can be deployed for all fine link coners applied in the textile industry.
Furthermore, the system described in the present invention reduces the repetitive
efforts of the operator of ring frame machine and increase in moral to challenge a
difficult task by reducing physical and mental efforts of the operators.
EXAMPLES:
The following example is presented for the purpose of illustrating the invention, and is
not intended to be limiting.
Reducing the rejection of low content bobbin and eliminating the idle time of the ring
frame machine resulted in the gain of 1738.8 kglmonth as described below.
The waiting time of the ring frame per doffing cycle is 6 minutes, and the doffing
cycle per day is 3.So the total waiting time per day per ring frame is 18 minutes. Also,
the production rate of ring frame is 8.4Kg per hour, and the total gain in production
comes out to be 2.52 Kg per day.
By employing all 23 machines, the total gain in production is 1738.8 Kg per month.
This accounted for a monetary benefit of Rs.30.36 Lac per year.
The preceding description has been presented with reference to various embodiments
of the invention. Persons skilled in the art and technology to which this invention
pertains will appreciate that alterations and changes in the described systems,
apparatuses, devices and methods of operation can be practiced without meaningfully
departing from the principle, spirit and scope of this invention.

We claim,
1. A system for reducing rejection of low content bobbins, in a yarn
manufacturing process, comprising:
(a) a blowing tube placed vertically and at an angle of blowing with respect to
the length of the bobbin; and
(b) an air blower coupled with the blowing tube.
2. A system for reducing rejection of low content bobbins as claimed in claim 1,
wherein the blowing tube is made of copper.
3. A system for reducing rejection of low content bobbins as claimed in claiml,
wherein the blowing tube has an angle of blowing within a range of 65" - 75 O.
4. A system for reducing rejection of low content bobbins as claimed in claiml,
, wherein the blowing tube is placed preferably at an angle of 70 " and at a height of 8
mm to the bobbin.
5. A system for reducing rejection of low content bobbins as claimed in claim 1
wherein, the blowing tube has a thickness of 0.2 mm.
6. A system for reducing rejection of low content bobbins as claimed in claim 1,
wherein the blowing tube has a length of 100 mm.
7. A system for reducing rejection of low content bobbins as claimed in claim 1,
wherein the blowing tube has an internal diameter of 6 mm.
8. A system for reducing rejection of low content bobbins as claimed in claim 1,
wherein the blowing tube has an orifice size of 0.5mm to maintain the air blow
velocity.
9. A system for reducing rejection of low content bobbin as claimed in claim 1,
wherein the blower coupled with the blowing tube blows a yarn vertically along the
length of the bobbin.
10. A method for reducing rejection of low content bobbins, in a yarn
manufacturing process, comprising the steps:
attenuating rovings at a ring frame machine in the yam manufacturing process,
where the rovings are spun and wound.to form yam bobbins;
feeding the yam bobbins to a link coner CBF from the ring frame machine to
inspect the yarn bobbins;
blowing the yarn bobbins using a blowing tube inclined vertically at an angle
of blowing to the yam bobbins, in a searcher at the link CBF, to find yarn end; and
feeding the checked bobbins to winding machine from the ring frame machine,
where the yam bobbins are spun and wound to form yam cones.
11. A method for reducing rejection of low content bobbins as claimed in claim
10, wherein the blowing tube is made of copper.
12. A method for reducing rejection of low content bobbins as claimed in claimlo,
wherein the blowing tube has an angle of blowing within range of 65' - 75 '.
13. A method for reducing rejection of low content bobbins as claimed in claimlo,
wherein the blowing tube is placed preferably at an angle of 70 ' and at a height of 8
rnrn to the bobbin.
14. A method for reducing rejection of low content bobbins as claimed in claim
10, wherein, the blowing tube has a thickness of 0.2 mm.
15. A method for reducing rejection of low content bobbins as claimed in claim
10, wherein the blowing tube has a length of 100 mm.
16. A method for reducing rejection of low content bobbins as claimed in claim
10, wherein the blowing tube has an internal diameter of 6 mm.
17. A method for reducing rejection of low content bobbins as claimed in claim
10, wherein the blowing tube has an orifice size of 0.5mm to maintain the air blow
velocity.
Dated 1 2th day of July, 20 13
TRIDENT LIMITED
by their attorney
&ylx 9 RAJ N AILAVAD
of CIP LEGIT