DESC:FEEDING APPARATUS FOR A TEXTILE BLENDING MACHINE
FIELD OF THE INVENTION
[0001] The present invention relates to an apparatus for blending at least two different textile fibres in a spinning preparatory machine. Particularly, the present invention relates to an improved feeding apparatus for weighing and blending of fibre flocks in a textile fibre blending machine.
BACKGROUND OF THE INVENTION
[0002] The subject matter discussed in the background section should not be assumed to be prior art merely because of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may correspond to implementations of the claimed technology.
[0003] In a textile spinning mill, physical and chemical properties of raw materials used are heterogeneous in nature. Different production process for natural and synthetic fibres leads to the heterogeneous characteristics of textile fibres. The textile spinning mills typically include a preparatory machine line, especially blow-room machines that are the deciding area for blending of the fibres in order to attain a spun yarn having preferred blending characteristics. The blending process is carried out at a textile spinning mill for the purpose of homogeneous mixing of various types of synthetic fibres, natural fibres, regenerated fibres, waste fibres, or a combination thereof. The blending process is an important process in yarn production which combines fibres of different origins, length, thickness or colour to produce a desired resultant yarn. Blending can be accomplished at the blow-room machine (flock blending), at a carding machine, at an open-end spinning machine (fibre blending), at a ribbon lap machine (web blending), at a draw frame machine or a sliver lap machine, at a combing machine (sliver blending) or at a ring spinning machine (roving blending). The flock blending process in the blow-room machine is the preferred method to mix various types of fibres intensively to compensate a variation in the characteristics of raw material in a spinning preparation process. Said homogeneous mixing of various types of textile fibres helps to achieve desired characteristics of a final yarn product at low cost.
[0004] In a conventional apparatus, fibres from various blow-room machines are fed to a blending machine by means of a feed duct arrangement. Compacted fibre material from the feed duct arrangement is passed in between a feed roller and a feed plate assembly, or through an arrangement of a pair of feed rollers. Further, the fibres are passed through an opening/beating roller, where the fibre flocks are opened. The opened fibre flocks are accurately weighed in a weighing bin or weighing container by means of a load cell. Thereafter, the weighed fibre flocks are conveyed by a conveyor belt of the blending unit in a batch process. In the blending unit, natural and synthetic fibres are intensively mixed at a desired blend ratio to attain desired homogeneous mixture of various fibres as per the required final yarn product.
[0005] In order to achieve the target weight at the weigh bin/container, speed of the feed roller is varied at three stages by a variable drive of the feed roller. The speed of the beating roller is maintained constant throughout the blending cycle. For the first few seconds of the process, the feed roller and the beating roller are driven at same speed. After some time, the speed of the feed roller is reduced, by keeping the speed of the beating roller constant. At last, the feed roller is driven at very low speed for a desired time to complete the blending process.
[0006] One such apparatus is well described in U.S. Patent No. US7075018, in which a weighing container preceded by a pre-filling chamber that is separated from the weighing container by a controllable flap. After weighing of the fibrous material, the weighed material is ejected from the weighing container onto a mixing conveyor belt. A material feed device is controlled in accordance with a theoretical weight curve given for each fibrous material component. Transport speed of the material feed device is varied in accordance with the theoretical weight curve. The theoretical weight curve provides total weight of the transported fibrous material at a given time in the weighing cycle, and is determined for each fibrous material component based on a predetermined relationship of feed rate of the transported fibrous material as a function of time over the course of the weighing cycle in order to achieve a theoretical total weight of fibrous material to be transported into the weighing container during the weighing cycle.
[0007] In general, a variation of draft in the blow-room machines and the carding machines ranges from 10-30%, whereas in the flock blending machine the draft variation is up to 750%, which significantly affects tuft size during the blending cycle in variable manner. The disadvantage of conventional apparatus is that the speed of the beating roller is not adjusted proportionately to the speed of feed roller, thereby leading to a drastic variation of draft between the feed roller and the beating roller. Constant opening of fibre tufts cannot be achieved due to the variation of speed between the beating roller and the feed roller, which ends up in drastic variation of the draft. In such a conventional apparatus, the tuft size variation within the weigh bin is very high, and the weigh-bin can only store up to 2000 grams of fibre material per cycle, especially for polyester. The variation of the tuft size, leads to de-blending, also referred to as fibre rupture, of the blended material while travelling through the feed duct. Thus, the draft variation affects the tuft quality as well as leads to reduction in overall production and blending efficiency of a textile blending machine. In the conventional apparatus, there is no solution given for reducing or eliminating the draft variation occurring during the blending process, which is disadvantageous towards production and blending efficiencies.
[0008] Therefore, there exists a need to address the above-mentioned shortcomings, to which the present invention provides an improved solution.
OBJECT OF THE INVENTION
[0009] An object of the present invention is to provide an improved feeding apparatus for a textile blending machine for maintaining a constant draft between a feed roller and an opening/beating roller.
[0010] Another object of present invention is to achieve uniform tuft size through constant opening of textile fibre flocks.
[0011] Yet another object of present invention is to improve production efficiency of the textile blending machine.
SUMMARY OF THE INVENTION
[0012] In order to achieve the above objectives, the present invention is provided with an improved feeding apparatus for a textile blending machine, and the aspects are further described below in the detailed description. This summary is not intended to identify essential features of the claimed subject matter, nor is it intended for use in determining or limiting the scope of the claimed subject matter.
[0013] The state of the art blending machines are associated with weighing system to accurately measure mass of fibre flocks. The accurate measurement of mass or density of textile fibres helps to blend various types of fibres at a desired blending proportion. The fibre material after various treatments in a blow-room line is transferred to a feed duct/feed chute of a blending machine. The fibre flocks from the feed chute are delivered to the feed roller through a feed plate assembly. Further the fibre flocks are fed through an opening/ beating roller, which aids in opening of fibre flocks. The well opened fibre flocks from the opening/beating roller are temporarily stored in a reserve chamber. The beating roller may be selected as a disc-type beating roller or a pin-type beating roller, depending upon the type of fibres to be blended. Once the reserve chamber is filled, control flaps of the weighing unit are opened and the fibres from the reserve chamber are delivered to the weighing unit. Thereafter, a direct measurement of weight is carried out in the weighing unit by means of an arrangement of load cells. The different types of fibres weighed at the weighing unit are dropped over a conveyor belt assembly in the range of 100 grams to 2000 grams per drop, especially for polyester material. Here the weighed fibres are dropped at the frequency of 3 times per minute. Then, the dropped fibre material is conveyed by the conveyor belt assembly to a blending unit of the textile blending machine. For an effective blending of different fibre tufts, the blending unit is provided with at least one stripper roller, a pair of feed roller and an opening roller. Based on the measured value, a first variable drive unit of the feed roller adjusts speed of feed roller at three stages to attain a target weight of delivery material at the weighting unit with an accuracy level of +/- 10 grams.
[0014] According to an embodiment of the present invention, the beating roller is provided with a second variable drive unit to adjust the speed of beating roller in proportion with the speed of the feed roller. The proportionate speed variation between the feed roller and the beating roller helps to attain constant draft throughout a blending cycle. The constant draft results in constant opening of the fibre material at a uniform tuft size.
[0015] In a conventional weighing unit of a textile blending machine, only 2000 grams of the fibre material can be stored in the weighing unit/container per cycle. However, according to the present invention, since a constant draft is maintained in the feeding apparatus of the textile blending machine, the fibre tufts are opened constantly at a uniform tuft size throughout the blending cycle, and are also able to store up to 3500 grams in the weighing unit. Thus, the present invention leads to store an additional 60-80% of the fibre material when compared to the conventional weighing unit. To this effect, production efficiency of textile blending machine is increased substantially.
[0016] Other aspects and advantages of the invention will become apparent from the following description, taken in conjunction with the accompanying drawings, illustrating by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0017] The accompanying drawings constitute a part of the description and are used to provide a further understanding of the present invention. Such accompanying drawings illustrate the embodiments of the present invention used to describe the principles of the present invention. The embodiments are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which references indicate similar elements. It should be noted that references to “an” or “one” embodiment in this invention are not necessarily to the same embodiment, and they mean at least one. In the drawings:
[0018] Fig. 1 illustrates an improved feeding apparatus of a textile blending machine according to an embodiment of the present invention;
[0019] Figs. 2A and 2B illustrate graphical representations of an operation of a conventional feeding apparatus of a textile blending machine, in accordance to the prior art;
[0020] Figs. 3A and 3B illustrate various graphical representations of an operation of the feeding apparatus, in accordance with an embodiment of the present invention; and
[0021] Fig. 4 represents an arrangement of a feed roller and an opening/beating roller of the feeding apparatus, according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The detailed description set forth below in connection with the appended drawings is intended as a description of various embodiments of the present invention and is not intended to represent the only embodiments in which the present invention may be practiced. Each embodiment described in this disclosure is provided merely as an example or illustration of the present invention and should not necessarily be construed as preferred or advantageous over other embodiments. The detailed description includes specific details for the purpose of providing a thorough understanding of the present invention. However, it will be apparent to those skilled in the art that the present invention may be practiced without these specific details.
[0023] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0024] The present invention relates to a feeding apparatus for a textile blending machine, capable of efficiently weighing and blending fibre flocks received from one or more blow-room machines. The feeding apparatus enables adjustment of speed of an opening/beating roller proportionately to the speed of a feed roller, to efficiently control a draft between the beating roller and the feed roller and prevent de-blending of the fibre material. This results in eliminating variation in the draft occurring during the blending process, thereby improving production and blending efficiencies.
[0025] Fig. 1 illustrates the feeding apparatus in the textile blending machine (1). The feeding apparatus includes a feed duct (2) through which textile fibre flocks after various treatments in one or more blow-room machines enters into a feed chute (3). The feed chute (3) compresses/compacts the fibre flocks. The compacted fibre flocks from the feed chute (3) are further processed by a feeding assembly including a feed plate assembly (5) and a feed roller (4). The feed plate assembly (5) includes one or more feed plates (5) for guiding the fibre flocks received from the feed chute (3) to the feed roller (4). The speed of feed roller (4) is controlled by a first variable drive unit (6). Due to closer setting between the feed roller (4) and the feed plate (5), short fibres are efficiently transferred and opened by an opening/beating roller (7) of the feeding apparatus. Depending upon the textile fibres, i.e., synthetic or natural fibres, disc-type or pin-type beating roller is used to open fibres without damaging the quality of the textile fibres. Further, the opened fibre flocks are dropped into the weighing unit/container (11), and excess fibre material gets automatically stored in at least one reserve chamber (9). The reserve chamber (9) has one or more control flaps (10) selectively movable to allow the excess fibre flocks stored therein to get transferred to the weighing unit (11). The weighing unit (11) is provided with a plurality of load cells (not shown) which are used to weigh the fibres accurately, and helps to achieve intense mixing of various types of textile fibres at a desired blend ratio. The weighed fibres from weighing unit (11) are conveyed to a blending unit (12) by means of a conveyor belt arrangement (not shown). The textile blending machine with one stripper roller and a pair of feed roller with an opening roller is used to mix the textile fibres in an appropriate blend proportion.
[0026] Figs. 2A and 2B show graphical representations of functioning of a conventional apparatus with respect to speed of the feed roller and the beater roller over time. In order to achieve a target weight with accuracy level of (+/- 10 grams) at the weighing unit (11), only the speed of the feed roller (4) is varied in three stages by a variable feed roller drive (6). However the speed of the beating roller (7) is maintained constant throughout the blending cycle. Due to the constant speed of the beating roller (7) and variable speed of feed roller (4), the draft between the feed roller (4) and opening/beating roller (7) is varied drastically from 800-6000 during this blending cycle. The drastic variation of draft leads to variation of tuft size and de-blending while travelling through the feed duct.
[0027] Fig. 3A illustrates a graphical representation of operation of the feeding apparatus, showing variation in the speed (metre per minute) of the feed roller (4) per unit time (seconds). Fig. 3B illustrates another graphical representation of operation of the feeding apparatus, showing variation in the speed (metre per minute) of the beater roller (7) per unit time (seconds). The draft between the feed roller (4) and beating roller (7) is maintained constant throughout the blending cycle. In order to maintain the constant draft, the speed of the beating roller (7) is varied in proportion with respect to the speed of feed roller (4) by using a variable speed drive means to drive the beating roller (7) as shown in Fig. 4. The variable speed of the beating roller (7) is achieved by using a second variable drive unit (8) which can be selected from variable speed electrical motors. The beating roller (7) is provided with the second variable drive unit (8) to adjust the speed of beating roller (7) in proportion with the speed of the feed roller (4). The proportionate speed variation between the feed roller (4) and the beating roller (7) helps to maintain constant draft throughout a blending cycle. Due to the constant draft, material openness is found constant at a uniform tuft size throughout the blending cycle. To this effect, the weighing unit (11) is able to store an additional 60-80% of material when compared to the conventional weighing bin/container, because of substantial reduction in weighing cycle time. Hence, an increased quantity of fibre storage is achieved. Thus, by using the feeding apparatus according to present invention, the textile blending machine (1) can store 3500 grams of textile fibres, especially for polyester fibre, which is higher volume for the conventional weighing container. Also, maintenance of the constant draft between the feed roller (4) and the beating roller (7) increases production efficiency of the textile blending machine (1) by 20%-26%.
[0028] In view of the present disclosure which describes the present invention, all changes, modifications and variations within the meaning and range of equivalency are considered within the scope and spirit of the invention. It is to be understood that the aspects and embodiment of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiment may be combined together to form a further embodiment of the disclosure.
[0029] List of Reference Numerals:
1 - Textile blending machine,
2 - Feed duct,
3 - Feed chute,
4 - Feed roller,
5 - Feed plate,
6 – First variable drive unit of feed roller,
7 - Opening/beating roller,
8 – Second variable drive unit of opening/beating roller,
9 - Reserve chamber,
10 - Control flap,
11 - Weighing unit,
12 - Blending unit.
,CLAIMS:We Claim:
1. A feeding apparatus for a textile blending machine (1), comprising:
a feed duct (2) for conveying a plurality of fibre flocks from one or more blow-room machines to at least one feed chute (3) configured to compress the plurality of fibre flocks;
a feeding assembly (4, 5) for processing the compressed fibre flocks received from the at least one feed chute (3), the feeding assembly (4, 5) comprising at least one feed roller (4) with a first variable drive unit (6) configured to variably control speed of the at least one feed roller (4);
at least one beating roller (7) configured to open individual fibre flocks of the processed fibre flocks, and transfer the opened fibre flocks to a weighing unit (11) configured to weigh the opened fibre flocks; and
a blending unit (12) receiving the weighed fibre flocks, for blending the weighed fibre flocks at a pre-defined blend ratio,
wherein the feeding apparatus comprises a second variable drive unit (8) coupled with the at least one beating roller (7), configured to variably control speed of the at least one beating roller (7) in one or more stages, and
a draft between the at least one feed roller (4) and the at least one beating roller (7) is controlled by varying the speed of the at least one beating roller (7) in the one or more stages by the second variable drive unit (8) in proportion with the speed of the at least one feed roller (4).

2. The feeding apparatus as claimed in claim 1, wherein the draft between the at least one feed roller (4) and the at least one beating roller (7) is maintained constant by controlling the speed of the at least one beating roller (7) in proportion with the speed of the at least one feed roller (4).

3. The feeding apparatus as claimed in claim 1, wherein the fibre flocks from the at least one feed chute (3) are delivered to the feed roller (4) through a feed plate assembly (5).

4. The feeding apparatus as claimed in claim 1, wherein the at least one beating roller (7) is any of a disc-type beating roller and a pin-type beating roller.

5. The feeding apparatus as claimed in claim 1, further comprising at least one reserve chamber (9) for storing excess fibre flocks transferred from the at least one beating roller (7).

6. The feeding apparatus as claimed in claim 5, wherein the at least one reserve chamber (9) comprises one or more control flaps (10) selectively movable to allow the excess fibre flocks stored in the at least one reserve chamber (9) to be transferred to the weighing unit (11).

7. The feeding apparatus as claimed in claim 1, wherein the weighing unit (11) comprises one or more load cells configured to weigh the opened fibre flocks.

8. The feeding apparatus as claimed in claim 1, wherein the weighed fibre flocks are conveyed to the blending unit (12) by a conveyor belt assembly.

9. The feeding apparatus as claimed in claim 1, wherein the blending unit (12) comprises at least one stripper roller for blending the weighed fibre flocks.