CLIAMS:We claim:

1. A quatri-coiler gill box system comprises: a pair of creel guide, wherein the pair of creel guide are placed adjacent to each other over a main shaft, wherein the pair of creel guide further comprises: a feed plate, wherein the feed plate provides a path for a movement of a feed sliver; an auto-stop mechanism, wherein the creel guide activates the auto-stop mechanism to stop the gill box at the time of a sliver breakage, wherein the feed sliver specifically denotes a strand of fibres, wherein the sliver is fed into the quatri-coiler gill box through a plurality of bi-coiler cans, wherein each bi-coiler can comprises at-least two slivers; a feed guide, wherein the feed guide is connected in synchronization with the pair of creel guide, wherein the feed guide receives a sliver from the feed plate, wherein the feed guide avoids dislocation of the moving sliver into an unwanted zone; a drafting zone, wherein the drafting zone further comprises a drafting gear, wherein the drafting gear increases or decreases the draft ratio, wherein the drafting zone receives the sliver from the feed guide, wherein the drafting zone attenuates the sliver to meet a required weight of sliver; a delivery assembly, wherein the delivery assembly ensures the storage of the sliver in a plurality of storage cans after completion of the drafting, wherein the said system is enhanced to install two creel guide over the same shaft to promote the feed sliver through the bi-coiler cans, wherein the system is further enhanced to modify the drafting gear up to 82T.

2. The system as claimed in claim 1, wherein the system provides a high doubling of the number of slivers ranging from 10 to 20 facilitated through a design change in the creel guide.

3. The system as claimed in claim 1, wherein the system provides a low draft ranging from 3.1 to 9.1 facilitated through a design change in the drafting guide, wherein the draft variation is flexible, wherein the draft is increased or decreased on the basis of a sliver load.

4. The system as claimed in claim 1, the system has an increased production from 420 Kg/hr to 840 Kg/hr.

5. The system as claimed in claim 1, wherein an attachment of the delivery assembly decreases specific power consumption, wherein the power consumption reduces to 3.76 units per 840 kg of production per hour.

6. The system as claimed in claim 1, wherein system has a reduced production cycle time, wherein the reduced production cycle is in a range of 20% to 25% depending on the sliver load.

7. A method for maximizing a productivity of a quatri-coiler gill box, wherein the method comprises: modifying a design in a quatri-coiler gill box, wherein the design modification comprises: placement of a pair of creel guide adjacent to each other over a main shaft; changing the drafting gear in a drafting zone to 82T; implementing the modified design in the sliver production; blending a feed sliver, wherein the design modification increases the intake capacity of the quatri-coiler gill box, wherein the increase in an intake capacity increases a capacity of the blender by 12096 Kg per day; feeding the blended sliver to a bi-coiler gill box, wherein the bi-coiler gill box provides storage of the feed sliver in two cans, wherein the design modification in the creel guide increases an intake capacity of the quatri-coiler gill box, wherein the increase in the intake capacity increases a capacity of the bi-coiler gill box by 12441 Kg per day; feeding the canned sliver from bi-coiler gill box to the quatri-coiler gill box, wherein the sliver in two cans obtained from the bi-coiler gill box is fed simultaneously over a feed plate of the quatri-coiler, wherein the fed sliver is passed to the drafting zone through a feed guide; attenuating the sliver to meet a required weight in the drafting zone, wherein the sliver is passed from the drafting zone to the delivery assembly; storing the attenuated sliver in the storage cans through the delivery assembly; wherein the overall production of the quatri-coiler at 100% utilization for 24 hours is upto 20,160 Kg.

8. The method as claimed in claim 7, wherein the modification in the drafting gear provides high uniformity in the produced sliver, wherein the modification in the drafting gear reduces a U% to a range of 2.09% - 2.992%, wherein the lower value of the U% improves an evenness of the sliver.

Mumbai, 5TH day of July, 2013

For RAYMOND LIMITED
(BY their Agent)

VIPUL N. BHUTA
ADITYA & ASSOCIATES ,TagSPECI:A) TECHNICAL FIELD OF INVENTION
[001] The present invention generally relates to a mechanical system and particularly relates to a system and method for enhancing a production of a gill box. The present system more particularly relates to a system and method for maximizing a productivity of specifically but not limited to a gill box. The present invention more particularly relates to a system and method for maximizing a productivity of a recombing gill box by implementing a low draft and high doubling principles.

B) BACKGROUND OF THE INVENTION
[002] Traditionally, in the worsted spinning process, a homogeneous mixing of different blends of slivers are based on a high draft & low doubling principle, but this principle has a limitation while working at the high speed of the machine. The control of fibres in the working path of machine becomes less because of the high draft or the high no. of attenuation of the fibres and leads to lapping on the rollers and other mechanical parts of the machine.
[003] Gilling is a very important step in the process chain of the yarn manufacturing prior to the combing or the preparing step. There are a number of steps in the preparation stage such as blending of the fibres through the doubling process, aligning the fibres through the gill head, ensuring an even weight per unit length of the sliver to facilitate comb setting and continuously ensuring the hooks produced in carding are aligned in the correct way to minimize the breakage in the comb. The hooks need to be in the trailing position.
[004] One of the prior arts discloses a high speed gill box having an upper head and a lower head. Each of the upper head and the lower head contains a complement of individually unconnected faller bars constrained to move in a smooth closed loop path. Each head is constructed to engage the associated faller bars outside of the pinned area to guide the faller bars through the closed loop path. The cam tracks are provided outside of the faller bar guide paths for engaging a crank arm extending away from the main pinned portion of each faller bar to provide proper orientation as the faller bar moves along its fixed path. The sprocket drives are provided in each head for engaging some of the faller bars and pushing them along the closed loop path. The drive sprockets are mounted at the one end of the drafting zone while the idler sprockets are mounted at the other end of the drafting zone to facilitate the movement of the faller bars from the drafting zone. A driven crowder roll is provided ahead of where the faller bars are engaged by the drive sprockets to engage and crowd the bars together before they reach the drive sprockets. The crowding of the faller bars assures that each bar enters the drive sprocket smoothly. Since there may be a small separation between the faller bars at some point in the closed loop path, the crowder roll is necessary to assure high speed operation.
[005] However, the prior arts yield a low output from the preparatory gill boxes. Also the capital investment required to increase the productivity is very high. Further the gill box disclosed in the prior arts leads to a high lead time and generation of a large amount of waste products. Also the prior arts get limited in a creel capacity and a delivery of sliver which lowers the production efficiency. Further due to an implementation of high draft, the breakage of the fibres is very high.
[006] In the view of foregoing, there is a need for a system and method for yielding a high output from the preparatory gill boxes. Also there is a need for a system and method for production of a sliver with low lead time and hence resulting in least generation of the waste products. Further there is also need for a system and method for implementing a principle of low draft to avoid breakage of the fibres.
[007] The above mentioned shortcomings, disadvantages and problems are addressed herein, as detailed below.

C) OBJECTS OF THE INVENTION
[008] The primary object of the present invention is to provide a system and method for maximizing the productivity of a gill box through the implementation of a low draft and high doubling principle. The objective is further extended to modify a design of the gill box to a quatri-coiler in order to obtain the low draft and high doubling principle.
[009] Another object of the present invention is to provide a system and method for increasing the efficiency of the gill box at a high speed.
[0010] Yet another object of the present invention is to provide a system and method for reducing the waste generation during the gilling operation.
[0011] Yet another object of the present invention is to provide a system and method for consuming less power during a production process and thus increasing the production life as well as efficiency. Further the objective is extended to reduce the installation, maintenance and running cost through the unique design of the gill boxes.
[0012] These and other objects and advantages of the embodiments herein will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings.

D) SUMMARY OF THE INVENTION
[0013] The various embodiments of the present invention disclose a recombing quatri-coiler gill box system. The system comprises a pair of creel guide, a feed guide, a drafting zone and a delivery assembly. The pair of creel guide is placed adjacent to each other over a main shaft. The pair of creel guide further comprises a feed plate and an auto-stop mechanism. The feed plate provides a path for a movement of a feed sliver. The creel guide activates the auto-stop mechanism to stop the gill box at the time of a sliver breakage. The feed sliver specifically denotes a strand of fibres. The sliver is fed into the quatri-coiler gill box through a plurality of bi-coiler cans. Each bi-coiler can comprise at-least two slivers. The feed guide is connected in synchronization with the pair of creel guide. The feed guide receives a sliver from the feed plate. The feed guide avoids dislocation of the moving sliver into an unwanted zone. The drafting zone further comprises a drafting gear. The drafting gear increases or decreases the draft ratio. The drafting zone receives the sliver from the feed guide. The drafting zone attenuates the sliver to meet a required weight of sliver. The delivery assembly ensures the storage of the sliver in a plurality of storage cans after completion of the drafting. A design of the said system is enhanced to install two creel guides over the same shaft to promote the feed sliver through the bi-coiler cans. The design is further enhanced to modify the drafting gear up to 82 Tesla.
[0014] According to one embodiment of the invention, the said system provides a high doubling of the number of slivers ranging from 10 to 20.
[0015] According to one embodiment of the invention, the said system provides a low draft ranging from 3.1 to 9.1 in the drafting gear. The draft variation is flexible i.e. the draft is increased or decreased on the basis of a sliver load.
[0016] According to one embodiment of the invention, the system has an increased production from 420 kg/hr to 840 kg/hr. The production increase due to the design modification is at-least twice than production provided by a bi-coiler gill box design.
[0017] According to one embodiment of the invention, an attachment of the delivery assembly decreases the specific power consumption. The specific power consumption reduces to 3.76 units per 840 kg of production per hour.
[0018] According to one embodiment of the invention, the design modification reduces the production cycle time by a range of 20% to 25% depending on the sliver load.
[0019] The embodiments of the present invention disclose a method for maximizing productivity of a recombing quatri-coiler gill box. The method comprises modifying a design in a quatri-coiler gill box. The design modification comprises placing a pair of creel guide adjacent to each other over a main shaft and changing the drafting gear in a drafting zone to 82T. The method further comprises implementing the modified design in the sliver production and blending a feed sliver. The design modification increases the intake capacity of the quatri-coiler gill box. The increase in an intake capacity increases a capacity of the blender to 12096 Kg per day. The method further comprises feeding the blended sliver to a bi-coiler gill box. The bi-coiler gill box provides storage of two slivers in one can. The design modification in the creel guide increases an intake capacity of the quatri-coiler gill box. The increase in the intake capacity increases a capacity of the bi-coiler gill box to 12441 Kg per day. The method further comprises feeding the canned sliver from the bi-coiler gill box to the quatri-coiler gill box. The sliver in two cans obtained from the bi-coiler gill box is fed simultaneously over a feed plate of the quatri-coiler gill box. The fed sliver is passed to the drafting zone through a feed guide. The method further comprises attenuating the sliver to meet a required weight in the drafting zone and storing the attenuated sliver in the storage cans through the delivery assembly. The sliver is passed from the drafting zone to the delivery assembly. The overall production of the quatri-coiler increases to 16,128 Kg per day. The maximum capacity at 100% utilization for 24 hrs is upto 20,160 Kg.
[0020] According to one embodiment of the invention, the modification in the drafting gear brings high uniformity in the produced sliver. The modification in the drafting gear reduces a U% to a range of 2.09% - 2.992%. The lower value of the U% improves an evenness or uniformity of the sliver.
[0021] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

E) BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The other objects, features and advantages will occur to those skilled in the art from the following description of the preferred embodiment and the accompanying drawings in which:
[0023] FIG. 1 illustrates a schematic side view of the recombing quatri-coiler gill box, according to one embodiment of the present invention.
[0024] FIG. 2 illustrates a schematic top view of the recombing quatri-coiler gill box, according to one embodiment of the present invention.
[0025] FIG. 3 illustrates a schematic front view of the delivery assembly, according to one embodiment of the present invention.

F) DETAILED DESCRIPTION OF DRAWINGS
[0026] FIG. 1 illustrates a schematic side view of the recombing quatri-coiler gill box, according to one embodiment of the present invention. With respect to FIG. 1, the quatri-coiler gill box 100 comprises a pair of creel guide 101, a feed guide 102, a drafting zone 103 and a delivery assembly 104. The pair of creel guide 101 is placed adjacent to each other over a main shaft. The pair of creel guide 101 further comprises a feed plate (not shown) and an auto-stop mechanism (not shown). The feed plate provides a path for a movement of a feed sliver. The creel guide 101 activates the auto-stop mechanism to stop the gill box 100 at the time of a sliver breakage. The feed sliver specifically denotes a strand of fibres. The sliver is fed into the quatri-coiler gill box 100 through a plurality of bi-coiler cans. Each bi-coiler can comprises of two slivers. The feed guide 102 is connected in synchronization with the pair of creel guide 101. The feed guide 102 receives a sliver from the feed plate. The feed guide 102 avoids dislocation of the moving sliver into an unwanted zone. The drafting zone 103 further comprises a drafting gear 105. The drafting gear 105 increases or decreases the draft ratio. The drafting zone 103 receives the sliver from the feed guide 102. The drafting zone 103 attenuates the sliver to meet a required weight of sliver. The delivery assembly 104 ensures the storage of the sliver in a plurality of storage cans after completion of the drafting. A design of the said system is enhanced to install two creel guides 101 over the same shaft to promote the feed sliver through the bi-coiler cans. The design is further enhanced to modify the drafting gear 105 up to 82T.
[0027] FIG. 2 illustrates a schematic top view of the recombing quatri-coiler gill box, according to one embodiment of the present invention. With respect to FIG. 2, the positions of the pair of creel guide 101, the feed guide 102, the drafting zone 103 and the delivery assembly 104 can be seen.
[0028] FIG. 3 illustrates a schematic front view of the delivery assembly, according to one embodiment of the present invention.
[0029] According to one embodiment of the present invention, the quatri-coiler gill box is fed by the bi-coiler cans which contain 2 slivers in one can. The slivers are transferred through the creel guide that facilitates the sliver to pass through the feed plate to the feed guide. The feed guide can be adjusted according to the feed load and bulkiness of the sliver (strand of fibres). The same sliver is drafted by means of a faller drafting system. The delivered sliver is then passed through the coiler to the cans. The weight per unit length i.e. wrapping of sliver can be increased or decreased by means of a flexible draft to meet the quality parameters of the pre-comb sliver. Because of the change in design, the quatri-coiler gill box is now equipped to take care of doubling (no. of slivers) to 20 instead of 10 and draft range to a range of 3.1 - 9.1 instead of 4.1 - 11.9. As the draft is less, control over movement and production of the fibres is better which leads to enhanced performance of the quatri-coiler gill box. The attachment of the delivering assembly ensures more output in the same time period with very less power consumption. By change in the thickness of the creel guide, sufficient space is created which ensures easy flow of the material inside the drafting zone.
Table No. 1 showing the U% for different machine design
Sl. No. Shade No. U% of Bi-coiler Gill Box U% of Quatri-Coiler Gill Box
1 243-94208 3.3 2.45
3.08 2.38
2.2
2.53
2 241-73766 3.23 2.92
3.41 2.09
2.44
2.37
3 271-86474 3.03 2.18
4.25 2.3
2.67
2.31

[0030] According to one embodiment of the present invention, the modification in the drafting gear introduces high uniformity in the produced sliver. The modification in the drafting gear reduces a U% to a range of 2.09% - 2.992%. The lower value of the U% improves an evenness of the sliver.
Table No. 2 showing a difference in production and power consumption for a Bi-Coiler gill box and a Quatri-coiler gill box
Machine Production/Hr Power consum/Hr
Bi-Coiler (GE1) 420 Kg 3.6 Unit
Quatri Coiler (GE2) 840 Kg 3.76 Units

[0031] From Table No. 2, it is clear that the specific power consumption per Kg per hour is about 80%-90% less in the quatri-coiler gill box with respect to that in bi-coiler gill box.

Table No. 3 showing industrial results obtained from the study of Power Consumption in Quatri-Coiler Gill Box
Date
E/M Reading DIFF UNIT MF-1 H/M READING DIFF KW PER HOUR
09-10-2011 385844 25665.72
10-11-2012 385866 22 22 25672.07 6.35 3.46
12-10-2011 385884 18 18 25676.85 4.78 3.77
13-10-2011 385909 25 25 25683.14 6.29 3.97
14-10-2011 385925 16 16 25687.3 4.16 3.85
AVG. KW PER HOUR 3.76

[0032] According to one embodiment of the present invention, despite of increase in the creel capacity, length of the quatri-coiler gill box doesn’t change. In contrary to that, less overall space is required by the present system.
Table No. 4 shows a parametric difference in Quatri-coiler gill box before and after the modification
Parameters Before After
Doubling at Blender 9x2x1=18 9x2x1=18
Draft at Blender 3.07x4.3=15.9 3.7x4=14.8
Doubling at GE-1 8 8
Draft at Blender GE-1 8 7.5
Doubling at GE-2 8 16
Draft at GE-2 8 4.5
Total Draft 15.9x8x8=1017.6 14.8x7.5x4.5=499.5
Total Doubling 18x8x8=1152 18x8x16=2304
Draft 6.5-7.5 4.2-5.5
Doubling(no. of sliver/strand) 6 or 8 16-20
Working width 200mm-220mm 220mm-260mm
Creel capacity 10(max.) 20(max.)
Can required 1 2
Delivery of sliver 2 4
Time to deliver material More Less

[0033] It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the claims.

G) ADVANTAGES OF THE INVENTION
[0034] The present invention prevents the breakage of sliver when the quatri-coiler system is running at a specific speed by implementing the auto-stop mechanism in the creel guide. Also, the present invention consumes less power and hence enhances the overall performance and efficiency. Further, the present invention facilitates high production capacity by implementing the design modification in the quatri-coiler gill box system. Further the present invention provides high evenness in the produced sliver.
[0035] Although the embodiments herein are described with various specific embodiments, it will be obvious for a person skilled in the art to practice the invention with modifications. However, all such modifications are deemed to be within the scope of the claims.
[0036] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the embodiments described herein and all the statements of the scope of the embodiments which as a matter of language might be said to fall there between.

Mumbai, 5TH day of July, 2013

For RAYMOND LIMITED
(BY their Agent)

VIPUL N. BHUTA
ADITYA & ASSOCIATES