SILK YARN REELING MACHINE (ANNA MACHINE)
FIELD OF THE INVENTION
The present invention relates to a reeling machine and more particularly a simple, low cost and
efficient Tasar silk yarn reeling machine adapted to produce un-twisted reeled silk yarn of
consistent superior quality wherein inserting twist can be need based, driven only by electric
motor at high speed with reduced power consumption.
BACKGROUND OF THE INVENTION
It is known in the related art that Silkworm cocoons are the protective shell made by the
silkworm to overcome the adverse weather and are alive for a period of more than one year that
is used as the source of raw material for silk filaments for producing yarn. It is made of a single
continuous silken filament (a protein, fibroin in the core, serecine in the outer layer) and some
gummy substances.
It is also known in the art of producing silk yarn from cocoons, reeling is the process of
unwinding of the filament from the cocoon and inserting twist optionally according to
requirements in filaments drawn together from equal number of cocoons. It is common process
to carry out pre-reeling treatment of cocoons to remove the gummy substances and thus the
treated cocoons have only the continuous single filament left. Only whole-cocoons with
continuous filament are used for reeling for producing yarn. Single filament from a cocoon is too
thin and weak to use as such, thus one single filament each from 8-10 cocoons are un-winded
from the cocoons and twisted, if required, together to form reeled yarn which is thicker and
stronger than individual filaments. The producer/operator has to de-floss the discontinuous filaments at the surface of the cocoon
and find the single end of the continuous single filament, for feeding them together in the
machine at the beginning or as and when required, if one is cut in between, to maintain the
number of filaments to 8-10 throughout the reeling process and of course operating the machine.
The machine drags the individual filament from each cocoon continuously after feeding of that
cocoon in the machine by the producer/operator, inserting twists, if required, in such 8-10
filaments together, spreading the yams throughout the bobbin while wrapping the yams in the
bobbin in a cris-cross manner so that the fine yams are not mingled with each other that help in
further unwinding from the bobbin during weaving or further processing.
In earlier days this entire operation was done manually by using thigh and palm and the Latai in
place of bobbin.
With the advent of mechanization of reeling process for producing yam, the prior art machines of
size having 990 mm wide, 970 mm deep and 1570 mm high and the weight of75 kilograms had
been in use. In this machine, the filaments are guided through a thread guide, where the filaments
come together. After going to the thread guide, the filaments are going to the crosier pulley,
which is held by the crosier pulley holder. After passing the crosier pulley the thread goes behind
the synthetic cot roller and is guided in front of the hindelium roller. The cot roller is held in a
holder which prevents the twist below to pass beyond it. A ring rail contains four rings of 5
centimetres diameter. In conjunction with a traveller the yam is twisted and wounded on the
bobbins, which are mounted on the spindle. Because of the moving ring rail the yam is uniformlyspread onto the bobbin over six inches (15 cm). The motion to the flywheel is provided by two
split pedals and levers or by a 190W motor with speed of 1440 revolutions per minute at a
voltage of 240V, connected to pulleys. The flywheel is beard by two rolling bearings and is
driving the aluminium spindle drive wheel (back pulley) by a polypropylene cord of diameter
4mm. The spindle drive wheel is fixed in the machines with bolts and runs smoothly on rolling
bearings. A little pulley fixed on the same axis as the flywheel is driving the compound pulley,
which is also done by a polypropylene cord. However, the prior art machines suffer from
problems relating to production at slow rate, poor and inconsistent yam quality and complexity
of the reeler operation. Such problems lead to low profitability compared to the time invested.
The earnings out of reeling per day are much lower compared to the local wage rate.
160S/CHE/2005 is a prior Indian patent that talks about a hand operated yam re-reeling
mechanism in which a traverse mechanism is positioned in front of a horizontal swift. The
invention relates to a re-reeling machine to produce better quality yam for making a skein/hank
wound with diamond pattern for unreeling during subsequent use. The yam passes from the
bobbins to the fixed thread guides and traversing thread guides and then to a tension roller. The
yam to be re-reeled is kept in a plurality of bobbins passes through fixed thread guides and
traversing thread guides and then on to the swift to form skein/hank. The yam of this prior patent
is the source material that is wound in bobbins whereas in the present invention the yam is
produced from multiple filaments from cocoons as the source. Further, the feature of the cited
patent comprising of a swift for presetting the diameter does not fall within the scope of the
present invention. Such problems of the prior art comprised poor efficiency and loss of energy, failure of fiber
materials/parts, higher operating costs relating to the machine. Problems inherent to production
process comprised Time loss due to slow rate or idling of machine, generation of huge Silk
Wastes, inability to produce untwisted yarns or to selectively introduce twist in yarn according to
need. Moreover, the yarn quality suffered from inconsistent quality or deterioration of quality
due to non-uniform thickness and colour of yarns produced. The reeler/producer was not in a
very comfortable position to use the reeling machine for lack of ergonomic design
considerations. This caused back problems and muscle pain although, all parts of the yarn guided
through are easily reachable by the reeler/producer. The prior art machine created excessive
noise so that long exposure to such noise may cause hearing problem of the producers.
There has thus been a need in the art to developing a reeling machine to produce untwisted
reeled silk yarn of consistent quality in a simple, cost effective yet highly efficient manner using
motor powered drive to run the machine with improved productivity. The machine would be
capable of eliminating the problems of the prior art relating to productivity, quality and economy
of operations. Advantageously, the device of the present invention is also intended to favor
delivering good yarn uninterruptedly taking care of problems relating to a yarn break, knots or
thicker yarns maintaining desired quality. There has been widespread demand also for such
machine:, which would be motor driven eliminating operator's interference and operational
hazards and adapted to produce better quality yarns through independently driven spindles. The
machine would be able to ensure smooth reeling of a plurality single filaments together to form
thick and stable un-twisted filament/thread to produce yarn and means for selective provisioning
of twist as necessary as well as combining the plurality of filaments drawn from independenttreated c:ocoons while passing through the thread guide in efficient manner without
compromising with quality.
OBJECTS OF THE INVENTION
The basic object of the present invention is thus directed to providing a cost effective, simple and
high effect reeling machine cost effective, simple and high effect adapted to produce un-twisted
reeled quality silk yarn wherein inserting twist can be need based.
Another object of the present invention is directed to providing a reeling machine to produce
untwisted silk yam wherein the twisting part has been separated and made optional, thus the
machine can produce un-twisted reeled yam.
A further object of the present invention is directed to providing a reeling machine to produce
untwisted silk yam wherein the device is run by electric motor eliminating the problem relating
to pedaling or other hazards related to manual operation.
A furtht:r object of the present invention is directed to providing a reeling machine to produce
untwisted silk yam wherein the silk filaments from a plurality of cocoons are passed through
thread guide buttons so as to maintain the thickness of the silk yam thread even when there is a
yam break, knots or thicker yams pass through the same.
A still further object of the present invention is directed to providing a reeling machine to
produce: untwisted silk yarn wherein the silk yam passes through the crosier pulley unit, whichfixes individual filaments, which are the wet yarns together to some extent in the yarn without
inserting any twist in it.
A still further object of the present invention is directed to providing a reeling machine to
produce untwisted silk yarn wherein a spreading mechanism is provided which oscillates up and
down to spread the yams over the bobbin vertically mounted over spindles as 'fishing net like
appearance' that helps the reeler to unwind the yams from the bobbin easily.
A still further object of the present invention is directed to providing a reeling machine to
produce untwisted silk yam wherein the spindle drive is very smooth and having less friction so
as to consume less power.
A still further object of the present invention is directed to providing a reeling machine to
produce untwisted silk yam wherein a break mechanism is connected with individual bobbin so
that in case of a problem of break cable with one of the spindle, that particular bobbin can be
disengaged from the spindle immediately by pressing the break button, while the other spindles
would be working normally and after mending the disengaged spindle, the same break button is
pressed to restart that particular bobbin.
A still further object of the present invention is directed to providing a reeling machine to
produce untwisted silk yam wherein said machine is adapted to reduce the power consumption to
25 watt (both AC and DC). SUMMARY OF THE INVENTION
The basic aspect of the present invention is directed to a silk yarn reeling machine to produce untwisted
quality reeled silk yam, comprising:
thread guiding buttons through which the fila}llents are passed to maintain uniform
thickness of the silk yam thread even when there is a yam break, knots or thicker yams
pass through the same;
a crosier pulley unit which fixes individual wet filaments from a plurality of treated
cocoons together to form a single filament yam without inserting any twist in it;
a drive unit comprising a plurality of spindles wherein each of the spindles are fixed
vertically and connected with the motor through pulleys and belts;
a spreading mechanism, which oscillates up and down to spread the yams into the each
bobbin vertically mounted over spindles and then finally wrapped in specially developed
wooden bobbins;
break mechanism which is connected with individual bobbin such that any particular
bobbin can be disengaged from the spindle immediately by pressing the break button in
case of a breakage in the yams in that bobbin, while the other spindles work normally
and the same break button can be pressed to restart that particular bobbin after mending
the yam in the disengaged spindle; and
a frame assembly to house the said units/mechanisms and the electric drive motor.
Another aspect of the present invention is directed to a silk yarn reeling machine to produce untwisted
quality reeled silk yam, wherein the yam spread mechanism comprising the thread
guides mounted on a horizontal plate connected through two vertical connecting rods with twovertical, circular pulleys, fixed at two ends of a horizontal shaft. This shaft is attached to the
main vertical shaft through a bevel gear. The horizontal plate along with the thread guides, each
in front of a bobbin oscillate up and down makes the spreading mechanism smoother to thereby
wind the filament evenly on each bobbin of desired pattern and thickness.
A further aspect of the present invention is directed to a silk yam reeling machine to produce untwisted
quality reeled silk yam, adapted to enhance the speed of spreading of yam on bobbin
wherein said spreading mechanism comprising:
a bevel gear fitted on horizontal shaft receiving power from vertical spindle shaft driven
by motor connected with belt pulley;
two round shaped pulleys mounted at two ends of said horizontal shaft rotating vertically;
each of said pulleys are connected with a vertical shaft through small connecting rods so
that on rotation of the horizontal shaft, said vertical shafts oscillate up and down very
fast; and
a horizontal plate, mounted at the top of said two vertical shafts, caITylng specially
designed thread guide situated close to each bobbin to ensure spreading of the yam over
bobbin at faster speed.
According to yet another aspect of the present invention is directed to a silk yam reeling machine
to produce un-twisted quality reeled silk yam, wherein during running of the machine the same is
adapted such that the yam get inside the specially designed thread guide automatically and move
up and down very fast to favour spreading of the yam over bobbin winded with fishing net
appearance. A still further aspect of the present invention is directed to a silk yarn reeling machine to produce
un-twisted quality reeled silk yarn, wherein said break mechanism comprises the shape of the
individual vertical spindle tapering upwards and the bobbin having similar groove inside such
that by pulling operatively the bobbin slightly upwards by the bobbin pusher of the break
mechanism with pressing of break button corresponding to a bobbin, the bobbin get disengaged
from the spindle and stops.
Importantly, in said silk yarn reeling machine to produce un-twisted quality reeled silk yarn, said
vertical spindles are booster with spindle adapted to run smoothly with minimum friction
consuming less power.
According to yet another aspect of the present invention directed to said silk yarn reeling
machine to produce un-twisted quality reeled silk yarn the same is optionally comprising means
adapted for generating the twisting part.
A still further aspect of the present invention is directed to a silk yarn reeling machine to produce
un-twisted quality reeled silk yarn comprising rheostat means adapted to favour the user of the
machine to fix the maximum speed of the machine through rheostat in case of DC supply so that
the machine can be handled comfortably.
A still further aspect of the present invention is directed to a silk yarn reeling machine to produce
un-twisted quality reeled silk yarn, wherein the device is adapted to reduce the power
consumption to 25 watt, both AC and DC. A still further aspect of the present invention is directed to a silk yarn reeling machine to produce
un-twisted quality reeled silk yarn, wherein the reeling machine comprised a plurality of units,
preferably four units, comprising said different mechanisms/assemblies for reeling of silk yam.
Advantageously, said silk yam reeling machine to produce un-twisted quality reeled silk yam
according to the present invention, is adapted such that the twist can be inserted in filaments
according to need.
The present invention and its objects and advantages are described in greater details with
reference to the following accompanying non limiting illustrative drawings.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Figure 1: is the schematic illustration of an embodiment of the reeling machine according to the
present invention showing the assembly of the different functional units and components of the
device having bevel gear drive and their respective locations in the arrangement.
Figure 1A: is the schematic illustration of another embodiment of the reeling machine according
to the present invention showing the assembly of the different functional units having bevel gear
drive system for faster reeling operation.
Figure 2: is the schematic illustration of the drive unit showing the disposition of the motor drive
shaft, the spindle shafts, the carn-shaft, the pulleys, V-belts and the disc cam for providing
required motion to the spindle/bobbin for producing yam and winding on bobbin. Figure 3: is the schematic illustration of the break: mechanism for engaging/disengaging of the
spindle drive for a particular bobbin in case of break filament problem by the operation of break:
button.
Figure 4: is the schematic illustration of the frame assembly used in the reeling machine showing
the different components and their respective positions in the assembly.
DETAII..ED DESCRIPTION OF THE INVENTION WITH REFERENCE TO THE
ACCOMPANYING DRAWINGS
The present invention is directed to providing a device for producing un-twisted reeled silk yam
adapted to inserting need based twist ensuring cost effective, simple and high effect operation of
such a device driven by an electric motor to produce quality silk yam. The device is capable to
produce un-twisted silk yam, wherein the twisting part has been separated and made optional,
thus the machine can produce un-twisted reeled yam.
Reference is first invited to the accompanying Figure 1, that schematically illustrate an
embodiment of the reeling machine of the present invention capable of producing untwisted
reeled silk yam, wherein the device is run by an electrical motor (1) of suitable rating, free of any
manual operation and related hazards. It is evident from the accompanying Figure 1 that the
device utilizes a bevel-gear (2) drive for the yam spreading mechanism (3) for uniform winding
of yam on bobbin mounted on independent vertical spindles. The device is run only by an electric motor (1) to produce un-twisted silk yarn eliminating the
requirement of conventional pedaling. After de-gumming treatment of the raw cocoons and
subsequent de-floss, the cocoons are kept in tray and single filaments from 8-10 cocoons passes
through thread guides operated by thread guiding buttons( 4) which maintains the thickness of the
silk yarn thread even when there is a yarn break, knots or thicker yarns pass through the same.
The silk yarns are made to pass through the crosier pulley unit (5), which fixes individual
filaments together to some extent in the yarn as the yarns are wet, without inserting any twist in
it. Then the yarn passes through the spreading mechanism (3), which oscillates up and down at
very fast speed to spread the yarns uniformly over the bobbin to produce a fish net type of
winding, vertically mounted over spindles (6) and then finally wrapped in specially developed
wooden bobbins (7).
According to said embodiment of the reeling machine of the present invention, the bevel-gear (2)
fixed on the vertical spindle-shaft (13) rotates two circular pulleys/cam (14), fixed at the two
ends of a horizontal shaft (15). The two cams are connected with two vertical shafts in its bottom
through connecting rods that ensures up and down oscillation of the spreading mechanism faster
According to another embodiment of the reeling machine as illustrated in accompanying Figure
lA, the yarn spreading mechanism has been modified for higher speed and low power
consumption. It has been observed that the up and down movement of the thread guide mounted
on horizontal plate that oscillate up and down being driven by means of worm gear drive
connected to two heart shaped pulleys, the spreading of yarn is slow and consuming more power. Thus the worm gear drive is changed to have a Bevel gear (18) fitted on a horizontal cam shaft
(17) receiving power from the drive shaft (22) of motor. The horizontal shaft having two round
shaped pulleys (19) mounted at its two ends rotating vertically. Each of these pulleys are
connected to a vertical shaft (20) fitted vertically through small connecting rods(21) such that
due to rotation of the horizontal shaft(17), the vertical shafts (20) oscillate up and down very fast.
A horizontal plate carrying the specially designed thread guide (23) situated close to each bobbin
has been mounted at the top of these two vertical shafts. When the machine is in running
condition, the yam get inside the specially designed thread guide automatically and moves up
and down very fast so as to ensure spreading of the yam over bobbin in fishing net like
appearance. This helps the reeler to unwind the yams from the bobbin easily. Also, the spindle
drive has been modified wherein booster with spindle is used to replace earlier spindles to
achieve smooth drive with less friction consuming less power. Advantageously, the device for
reeling silk yam has reduced the power consumption to 25 watt (both AC and DC).
The plurality of vertical spindles with pulleys mounted thereon is driven by the motor spindle
with drive pulley connected to said spindle pulleys (11) by belts (12). The drive unit of Figure 2
shows the arrangement of the motor driven spindles for providing rotary motion to the bobbins
for reeling of yam.
According to the embodiment of the device of Figure lA, to accommodate a break cable, a
break mechanism (8) is connected with individual bobbin (9). If there is a problem with one of
the spindle, immediately by pulling the break button (10), that particular bobbin (9) can be
disengaged from the corresponding spindle (6) while the other spindles would be workingnormally. After mending a disengaged spindle/broken yarn, the same break button (10) can be
pressed to restart that particular bobbin.
Further to achieve this, the shape of the individual spindle (6) is tapering upwards and the groove
of the bobbin (9) is having similar taper, such that by pulling the bobbin (9) slightly up with the
break mechanism (8) by the operation of the corresponding break button (10), the bobbin (9) get
disengaged from the spindle (6) and stops. The break mechanism has been illustrated in the
accompanying Figure 3. Each of the spindles (6) is fixed vertically on shafts connected with the
motor (1) through pulleys (11) and belts (12).
Reference is now invited to the accompanying Figure 4 that schematically illustrates the Frame
assembly of the machine and its different components. It is clearly apparent that the frame is
composed of plates and L-shaped angles. The frame comprise a front plate, a back plate, a top
plate, a base plate, two side plates and a level 1 plate placed intermediate to top plate and the
base plate, assembled in position supported by means of L-shaped angles. The plates are having
provisions for mounting of the different components/mechanisms e.g. crosier pulley unit, break
mechanism, spindles, horizontal and vertical shaft, threads guide mechanism etc. of the reeling
machine.
The reeling machine according to the present invention is having four units, each working in the
same manner wherein the each single filament from 8-10 tasar cocoons made to pass through a
yarn gatherer and then through a small slit to the crosier pulley assembly. Once the machine
runs, the thread gets into the specially developed thread guide mounted on the plate which movesup and down very fast and fmally reach to the rotating bobbin where the yam gets winded with
'fishing net' appearance. One can stop any of the bobbins to rotate by pressing the break button
and can stop the machine by pressing the switch fixed on the machine. The user of the machine
can fix the maximum speed of the machine according to requirement by adjusting a Rheostat
used for DC supply so that the machine can be handled comfortably.
It is thus possible by way of the present invention to developing a high-speed silk yam reeling
machine that is simple, cost effective and efficient device consuming less power. Importantly,
the silk yam reeling machine of the present invention would favour winding/reeling silk yam
free of twisting on the bobbin or inserting need based twisting, favoring easy unwinding during
subsequent use in weaving. Advantageously, the silk yam reeling machine using multiple
filaments drawn from a plurality of treated cocoons combined to form a single fiber/thread
wherein in case of a filament break, the corresponding spindle with bobbin can be immediately
stopped and disengaged for mending and it can resume operation after recombining with other
filaments and thus ensuring uniform thread thickness and consistent quality of yam. Further, low
friction spindle drive enable reducing power consumption of the device while still performing
reeling/winding of yam at very high speed. The device of the invention is thus capable of wide
scale use and application in the silk yam producing/processing industry with significant
economic advantage.
WE CLAIM:
1. A silk yam reeling machine to produce un-twisted quality reeled silk yam, comprising:
thread guiding buttons through which the filaments is passed to maintain uniform
thickness of the silk yam thread even when there is a yam break, knots or thicker yams
pass through the same;
a crosier pulley unit which fixes individual wet filaments from a plurality of treated
cocoons together to form a single filament yam without inserting any twist in it;
a drive unit comprising a plurality of spindles wherein each of the spindles are fixed
vertically and connected with the motor through pulleys and belts;
a spreading mechanism, which oscillates up and down to spread the yams into the each
bobbin vertically mounted over spindles and then finally wrapped in specially developed
wooden bobbins;
break mechanism which is connected with individual bobbin such that a particular
bobbin can be disengaged from the spindle immediately by pulling the break button in
case of a break cable while the other spindles work normally and the same break button
can be pressed to restart that particular bobbin after mending disengaged spindle; and
a frame assembly to house the said units/mechanisms and the electric drive motor.
2. A silk yam reeling machine to produce un-twisted quality reeled silk yam as claimed in
Claims 1 or 2, adapted to enhance the speed of spreading of yam on bobbin said
spreading mechanism comprising:
a bevel gear fitted on horizontal shaft receiving power from vertical spindle shaft driven
by motor connected with belt pulley; two round shaped pulleys mounted at two ends of said horizontal shaft rotating vertically;
each of said pulleys are connected with a vertical shaft through small connecting rods so
that on rotation of the horizontal shaft, said vertical shafts oscillate up and down very
fast; and
a horizontal plate, mounted at the top of said two vertical shafts, carrying specially
designed thread guide situated close to each bobbin to ensure spreading of the yarn over
bobbin at faster speed.
3. A silk yarn reeling machine to produce un-twisted quality reeled silk yam as claimed in
anyone of Claims 1 to 2, wherein during running of the machine the same is adapted such
that the yam get inside the specially designed thread guide automatically and move up
and down very fast to favour spreading of the yam over bobbin winded with fishing net
appearance.
4. A silk yam reeling machine to produce un-twisted quality reeled silk yam as claimed in
anyone of Claims 1 to 3, wherein said break mechanism comprises the shape of the
individual vertical spindle tapering upwards and the bobbin having similar groove inside
such that by pulling operatively the bobbin slightly upwards by the bobbin pusher of the
break mechanism with pulling of break button corresponding to a bobbin, the bobbin get
disengaged from the spindle and stops. 5. A silk yam reeling machine to produce un-twisted quality reeled silk yam as claimed in
anyone of Claims I to 4, wherein said vertical spindles are booster with spindle adapted
to run smoothly with minimum friction consuming less power.
6. A silk yam reeling machine to produce un-twisted quality reeled silk yam as claimed in
anyone of Claims 1 to 5, optionally comprising means adapted for generating the twisting
part.
7. A silk yam reeling machine to produce un-twisted quality reeled silk yam as claimed in
anyone of Claims 1 to 6, comprising rheostat means adapted to favor the user of the
machine to fix the maximum speed of the machine through rheostat in case of DC supply
so that the machine can be handled comfortably.
8. A silk yam reeling machine to produce un-twisted quality reeled silk yam as claimed in
anyone of Claims 1 to 7, wherein the device is adapted to reduce the power consumption
to 25 watt, both AC and DC.
9. A silk yam reeling machine to produce un-twisted quality reeled silk yam as claimed in
anyone of Claims 1 to 8, wherein the reeling machine comprised a plurality of units,
preferably four units, and comprising said different mechanisms/assemblies for reeling of
silk yam. 10. A silk yam reeling machine to produce un-twisted quality reeled silk yam as claimed in
anyone of Claims 1 to 9, adapted such that the twist can be inserted in filaments
according to need.
11. A silk yam reeling machine adapted to produce un-twisted quality reeled silk yam in a
simple, cost effective and efficient manner at faster speed and lower power consumption
substantially as herein described with reference to the accompanying illustrative
drawings.