Roving Frame

TT-2069
 Roving frame

• To understand the roving, first we

need to understand the yarn and
process flow of ring spinning
What is
spinning?
• Formation of fibres or filaments
from natural or synthetic
polymers

• Conversation of natural or
synthetic fibers and filaments
into yarns by twisting or other
means of binding together the
fibres or filaments.
• This provides a relatively fine
continuous length of thread that
has properties suitable for
conversion into a fabric form or
for use directly for sewing or
rope making.
 Yarn spinning

• A staple-spun yarn is a linear assembly of many fibres in the cross-section

and along the length, held together usually by the insertion of twist to
form a continuous strand, small in diameter but of any specified length.
• It is used for interlacing in processes such as knitting, weaving and sewing
 Yarn Spinning
• Hand spinning:
• ‘stringskirts’ dating back around 20,000 years ago
• wool was firstly spun
• without the use of tools
By stretching out a thin bunch of fibres with one hand (the attenuating action being
referred to as drawing) while twisting together the fibres of the attenuated length
between the fingers of the other hand
 Yarn Spinning

• Use of spindle for spinning This is a short stick around which the prepared fibrous
mass would be wrapped
Yarn Spinning
The spinning jenny
 Yarn Spinning
• Ring spinning frame, invented in 1832 by John Thorp

• continuous drafting, twisting and winding, and at much faster

production speeds than the intermittent drafting, twisting and winding
of mule spinning the most used method of yarn production even
Yarn Spinning
Comparison of various Spinning techniques
Roving Frame
• The roving frame reduces the linear
density (wt/unit length) of drawn silver
by drafting.
• After reducing the linear density the
silver is transfer into roving (a thin form
of rope).
• This is the first stage where the twist is
inserted to fibers in yarn manufacturing
process
Why drawn sliver cannot be used for yarn
manufacturing in Ring spinning???
Roving Frame
• Sliver is a thick, untwisted strand that tends to be hairy and to create
fly.
• The draft needed to convert this to a yarn is in the region of 300 -
500.
• The drafting arrangements of ring spinning machines, in their current
forms, are not capable of processing this strand in a single drafting
operation to create a yarn of short-staple fibers that meets all the
normal demands on such yarns
Roving Frame
• Drawframe cans are not the suitable mode of transport and
presentation of feed material to the ring spinning frame

• Sliver cans occupy large space in comparison to the space of one

spinning position of ring spinning frame, so there is need to have finer
strand wound on smaller packages, which the roving operation satisfy
 DEMANDS PLACED UPON THE MODERN ROVING FRAME

• Improvements required
• design needs less liable to faults
• increase in spindle rotation speeds
• larger packages
• automation of the machine and of package transport
Objective/tasks of roving frame
• Attenuation: Drafting the draw frame sliver into roving.
• Twisting: To inserts the twist into the roving.
• Winding: Winding the twisting roving on the bobbin.
• Package building
 Understanding Drafting & its types

• There are two types of drafting:

• Dispersion Drafting
• Roller Drafting
• Dispersion Drafting
• The type of drafting in which the material attains an irregular and
dispersed form is called dispersion drafting.
• Dispersion drafting mainly performs opening and cleaning actions.
Straightening and parallelization are also observed but to a short extent.
• Dispersion drafting takes place in blowroom, i.e. Scutcher & card machine.
 Understanding Drafting & its types
Roller Drafting
• The type of drafting in which a minimum of two pairs of rollers are used to
keep the material in a regular form, is called roller drafting.
• E.g. the regular form may be sliver, roving etc.
• Roller drafting mainly perform straightening and parallelization of fibers.
Opening and cleaning are not usually concerned in roller drafting .
• Roller drafting takes place on drawing frame, simplex & ring spinning
frame.
 Understanding Drafting & its types
• To decrease the wt/length: ????????

• The variation in weight / length of slivers or roving is called

irregularity.
• Poor drafting can increase the irregularities in the material
 Understanding Drafting & its types

Revolutions per Minute (rpm)

It is the number of revolutions covered by a roller in one minute.
The rpm of a roller is independent of the diameter of rotating element.
Surface speed
The distance traveled by a point on the surface of rotating element in a unit
time is called the surface speed of that rotating element.
Surface speed is also called linear speed. It is equal to
S.S. = πDN
Where D = diameter of rotating element
N = number of revolutions / min.
 Understanding Drafting & its types
• Roller Drafting
• Roller drafting in done by a minimum of two pairs of rollers. Usually,
• Top roller ------------------- covered with synthetic rubber
• Bottom roller -------------------- made of high carbon polished steel
• Roller Nip
• The area of contact b/w two rollers is called the roller nip.
• Roller nip is also called the nipping point. The top roller is covered
with synthetic rubber coating so that it increases the area of contact
b/w the two rollers. Larger nip means more frictional contact and
therefore less slippage b/w the two rollers.
 Understanding Drafting & its types

• Mechanical Draft
• Mechanical Draft= Surface speed of Front Roller /Surface Speed of
Back Roller > 1
• Actual Draft
• Actual Draft= Count Fed/Count Delivered (Direct System)
• Actual Draft= Count Delivered/Count Fed (Indirect System most
Common)
 Understanding Drafting & its types

• Those machines in which waste is removed. A.D > M.D

• Example: card, comber
• Mechanical draft is simply the mechanical ratio b/w two pairs of rollers
and is not concerned with the composition of the material passing
through it.
• Actual draft is the ratio b/w two counts. If the waste is also removed
while drafting, the difference b/w the count fed and delivered will be
increased and therefore the actual draft will also be increased.
 Understanding Drafting & its types

• Those machines in which twist is inserted. A.D < M.D

• Example: roving frame, ring frame
• After producing the twist, the difference b/w fed and delivered
counts decreases and hence the actual draft decreases.
 Understanding Drafting & its types
• Back Tension Draft:
• The draft b/w assisting rollers and back pair of roller is called back tension
draft. Tension draft provides tension to sliver for better nip of material in the
nips of assisting rollers and back pair of rollers. It can be calculated as;
• D=Surface Speed of back rollers/Surface Speed of assisting rollers
• Back Zone Draft or Break Draft
• The draft b/w middle and back pair of rollers is known as break draft. This
draft is called break draft as it is used to break the fiber arrangement or the
previous m/c i.e. entanglements of hooks which are necessary to remove for
further drafting. It is calculated as;
• D=Surface Speed of middle rollers/Surface Speed of back rollers
 Understanding Drafting & its types
• Main or Major Draft
• The draft b/w front and middle pair of rollers is called major draft. It is
given by
• D=Surface Speed of front rollers/Surface Speed of middle rollers
• Front Tension Draft
• It is the draft b/w calendar rollers and front rollers. This draft provides
sufficient tension to sliver to prevent its slackness (looseness). It can
be calculated as;
• D=Surface Speed of calendar rollers/Surface Speed of front rollers
• Total Draft= back tension X break draft X main draft X front tension
 Roving Frame
Creel is the place situated at the back of the
machine where the raw material is placed to be
fed to the drafting zone

Drafting is normally carried out by a draft system

with double apron capable of working with
entering sliver counts of 0.12-024 Ne and counts
of the delivered roving of 0.27—3 Ne

The draft given in the roving process will be in the

range between 4 and 20 and can work fibers of a
length of up to 60 mm.
Roving Frame
• The drafting arrangement attenuates the slivers with a draft of between 5
and 20.
• The strand delivered is too thin to hold itself together and a strength
imparting step is necessary immediately at the exit of the drafting
arrangement.
• This is performed by inserting protective twist usually in the range of 25 -
70 turns per meter.
• The turns are created by rotating flyer
• It is very important factor which produces strength in the roving and twist
is inserted with the help of flyer
• The turns are are transmitted into the unsupported length of roving
between the flyer and the delivery from the drafting arrangement.
• The flyer itself forms part of driven spindle and is rotated with the spindle.
Roving frame
• To ensure that the roving is passed safely and without damage to the
wind-up point, it runs through the flyer top and the hollow flyer leg,
and is wound 2 - 3 times around the presser arm before reaching
bobbin
• To enable winding to be performed, the bobbin is driven at a higher
peripheral speed than the flyer so that the roving is drawn off the
flyer leg
Roving Frame

Creel zone
• The function of the creel is to hold the
roving bobbin over a roller beam within a
convenient height to easily handle the
roving. The creel must permit free
running of the roving bobbins with slight
tension on it.
• Above the cans there are several rows of
driven rollers to help the slivers on their
way to the drafting arrangement, which
is often a considerable distance from the
cans.
•
Roving Frame
• Care must be taken to ensure that the slivers are passed to the
drafting arrangement without disturbance; that they are drawn, for
example, more or less vertically out of the cans; and that the guide
rollers run smoothly.
• The can diameter does not correspond to the spindle gauge, so the
cans are not arranged in one row but in several, which have to be set
out behind the machine
Roving Frame
• Drafting Zone
• The 3-over-4 cylinder system and the double-apron arrangement are
still to be found in modern machines offered by manufacturers.
• The 3-over-4 arrangement is found relatively rarely, while the double-
apron system is standard.
• Only the double-apron arrangement permits drafts of 20 while
holding the fibers more or less under control during their movements.
In general, three-cylinder arrangements are used, but four cylinders
may be needed for high drafts.
Three-cylinder, double-apron drafting arrangement
 Drafting Zone

• Three-cylinder arrangements are used,

but four cylinders may be needed for
high drafts.
• They usually comprise fluted lower
rollers and rubber coated pressure
rollers.
• The hardness of the upper rollers is
between 80° and 85° Shore
 Drafting Zone

• For higher draft applications 4/4

drafting system is used
• The range of draft is from 5 to 20
Drafting Zone

• Top rollers are synthetic rubber

coated Bottom rollers are made of
steel Front, 3rd and back rollers
(bottom) are spiral fluted. 2nd roller
has granulated pin.
• Front roller 2nd roller 3rd roller Back
roller Top roller 28 mm 25 mm 28
mm 28 mm
• Bottom roller 30-32 mm 25-27 mm
30-32 mm 30-32 mm
Drafting Zone
• The top roller must be pressed
with relatively high force
against the lower rollers to
ensure the guidance of fiber.
• Pressure are in the range of
100 to 250 N per roller which
may vary as per raw material
and its volume.
• Pressure is applied by spring
pressure, pneumatic weighting,
magnetic weighting.
Drafting Zone
Draft Zone
• Back draft is given in back zone which affects roving evenness.
• Less amount of draft is provided in middle zone where the condenser
is used to condense sheet like sliver.
• Maximum amount of draft is given in front zone where the apron is
used to move at the surface speed of the middle-roller pair
• Condenser???
• Aprons???
Draft Zone
• Aprons
• The upper aprons are short and made either of leather or more commonly of
synthetic rubbers. They have a thickness of about 1 mm and are held by
tensioning device.
• The lower aprons are longer and usually made of leather.
• They run over the guide bar, usually known as nose bar, to position close to the
delivery roller.
• Function: The aprons co-operated with each other to guide and transports the
fibers during drafting and they exert a very significant influence on the drafting
operations
 Drafting Zone
• The aprons cooperate with each other
to guide and transport the fibers during
drafting and they exert a very significant
influence on the drafting operation.
• It is important that the aprons should
extend as closely as possible to the nip
line of the front rollers.
• The guiding length, referred to as the
cradle length, must be adapted
approximately to the staple length.
Drafting Zone

Cradle length (mm) Material

short Cotton up to 1 1/8˝; 40 mm

synthetic fibers
medium Cotton above 1 1/8˝; 50 mm
synthetic fibers
long Synthetic fibers, 60 mm
 Drafting zone
• Condensers
• Condensers are mounted on a
reciprocating bar behind the drafting
arrangement.
• The second condenser is provided in
break draft field.
• And the 3rd one is located in main
draft field.
• Function: Spreading sliver masses are
condensed to improve evenness and
lead to drafting zone.
• Advantage: Reduce the high fly level
and hairiness of roving.
 The flyer inserts twist

Each flyer rotation creates one turn in the

Twisting roving
zone
Since the flyer rotation speed is kept
constant, twist per unit length of roving
depends upon the delivery speed and can
be influenced accordingly
Twisting zone
• High levels of roving twist represent production losses and might lead
to draft problems in the ring spinning machine.
• On the other hand, low twist levels can cause false drafts or even
roving breaks during bobbin winding
• Turns per meter:
Twisting zone
Twisting Zone
Twisting Zone
Twisting Zone
The imperfection index (IPI) is the sum of yarn thin places/ km (-50%), thick
places/km (+50%) and neps/km (+200%) per kilometer of tested yarn
Twisting Zone
• Best results in terms of unevenness (U%) and imperfection index (IPI)
value of 24Ne compact yarn were obtained by keeping the roving
hank of 0.90Ne, roving twist/meter of 40
• It is worth mentioning that finer roving of 0.90 Ne needs increased
level of twist to get a lower level of yarn imperfections (IPI) for 32Ne
compact yarn in comparison with 24Ne compact yarn
• Roving fineness should be increased with the increased level of yarn
fineness.
• There was a significant increase in yarn CSP value when the roving
fineness is increased with the increasing level of yarn fineness
Twisting Zone
• The productivity of roving frame depends upon the delivery speed
and the rotation speed of the flyer.
• The three flyer types exist:
Spindle-mounted flyers
Closed flyers
Top-mounted flyers
Twisting Zone
Twisting Zone
• Tasks of Flyer
• Provides twist to roving. It gives one twist on roving per revolution.
• Also, guide the roving in proper place over the bobbin during winding.
• Flyer maintains winding tension and produce a compact bobbin
Twisting
Zone
Parts of Flyer
 Twisting zone
• Flyer Top:
• The way in which roving carried along and guided at
the entrance to the flyer determines the degree of
twist and the winding tension.
• There is a risk of false drafts, so the strand passes
through the flyer top to the guide groove with half a
wrapping
• This wrap of roving permits better control of roving
tension and the package build becomes more even
owing to the harder coils
Twisting Zone
• The Presser Arm:
• Presser arm is attached to the lower end of the hollow flyer leg.
• The arm has to guide the roving from the exit of the flyer leg to the
package.
• The roving is wrapped two or three times around the it.
• The number of turns determines the roving tension.
• If this is high, then a hard, compact package is obtained. If it is too
high, false drafts or roving breaks can be caused. The number of
wraps depends upon the material and twist level
 Twisting Zone
• The legs of flyer:
• The flyer has to guide the very sensitive strand
from the flyer top to the package without
introducing false drafts
• The fibrous strand has low level of twist and is
very liable to break. Also, the flyer is rotating,
along with the roving, at a speed of up to
1500 rpm.
• Therefore, the fiber strand must therefore be
protected against strong air currents
 Twisting Zone
• The legs of flyer:
• One of the two flyer legs has usually been
hollow, i.e. with a deep guide groove that is
open in a direction opposite to the direction
of rotation. The strand is drawn through this
groove.
• The second, solid flyer leg serves to balance
the grooved leg
Twisting zone
• Materials of flyer:
• Earlier flyers were invariably made of steel, but they are now mostly
made of light alloy
• At the high speeds, normal steel flyers would spread at the legs
• This spreading effect the operation of winding
• The light alloy flyers have lower weight. Flyers can have varying sizes,
which are specified in inches
 Twisting Zone
Spindle-mounted flyers:
• The standard form has in the past been the spindle-
mounted flyer
• This is simple as far as design and drive are concerned
• But has the disadvantage in context to service and for
automation purposes
• The spindle is simply a support and drive element for the
flyer, without any ancillary function.
• It is a long steel shaft, mounted at its lower end in a bearing
and supported in the middle by the vertically reciprocating
shaft of the package tube acting as a neck bearing
Twisting Zone:
• Closed and Top mounted flyers:
• The closed flyer has been used only by Platt Saco
Lowell in the Rovematic machine.
• It has the advantage of reduced spreading of the legs at
high operating speeds.
• The standard design is the top-mounted flyer
• This form facilitates automation of the doffing
operation. The flyer is supported by ball bearings at the
neck and is driven by gear wheels or toothed belts
from above
 Why Winding is
important?

Winding Zone What is the shape

of roving package?

Why package shape

is important?
 Winding zone
• A roving bobbin is a cylindrical
body with tapered ends
• It is created by building layer upon
layer of parallel coils of roving on
wooden or plastic bobbin tubes
acting as package cores.
• To form the tapered ends, the
height of the lift must be reduced
after each layer has been
completed
Winding zone
• The roving bobbin is the ideal
package form for supplying
material to the ring spinning
frame
• The bobbin carries a
relatively large quantity of
material, owing to its
compactness
• It occupies a relatively small
volume, convenient for
transport and storage in
empty form
Winding zone

• Structure of roving package:

• The angle of taper of the ends is
normally between 80° and 95°,
and depends upon the
adherence of the material.
• The angle is made as large as
possible, so that as much roving
as possible is wound onto the
package.
• However, the angle must be
small enough to ensure that the
layers do not slide apart
Winding Zone
• During winding of a roving bobbin, the flyer rotation speed is usually
kept constant.
• The difference between the speeds of the flyer and the bobbin must
also be kept constant.
• However, the bobbin diameter increases stepwise, after each layer of
roving.
• The bobbin rotation speed must be reduced accordingly to maintain
the required difference between the speeds.
Winding zone
• Flyer lead system:
• Flyer surface speed is higher
• Flyer winds the roving on bobbin
• Bobbin Lead system:
• Bobbin surface speed is higher
• Bobbin wind the roving itself
• Bobbin lead system provides better stable structure
Winding Zone
• In both the cases, the spindle speed remains constant through out
the winding process, since changing the spindle speed will change the
twist in the roving.
• The bobbin speed is changed according to the requirement
• In both the cases, the roving delivery speed is constant decided by
the surface speed of the front pair of drafting rollers
• Hence, in case of bobbin lead method the bobbin speed has to be
gradually decreased and in the case of flyer lead the bobbin speed
has to be gradually increased in order to keep the roving tension
constant while winding the rovings on the bobbin.
 Winding zone
• Variation in bobbin speed
originates from the cone drums.
• When the builder motion shifts
the cone belt, the rotation speed
of the lower cone is changed.
• This declining rotation speed is
transmitted via gearing to the
differential and is there
superimposed on the constant
speed of the main shaft.
Winding zone
• Further gearing then
transmits the resulting
rotation speed to the bobbin
drive ( 4/3). On the bobbin
rail, bevel gears (4) fixed to
the longitudinal shaft drive
the bevel gears (3) of the
bobbin supports.
Winding Zone

• Builder Motion: has to perform

three important tasks during a
winding operation
• Shift the cone belt corresponding to
the increase in bobbin diameter
• Reverse the direction of movement
of the bobbin rail at the upper and
lower ends of the lift stroke;
• Shorten the lift after each layer to
form tapered ends on the bobbins.
Winding Zone
• The required moment for each change-over and the magnitude of the
adjustment both depend upon the roving hank and the material, and
must therefore be adapted to the prevailing conditions by means of
change gear positions.
• Most of the movement changes are effected electro-pneumatically.
Winding zone
• Package formation & machine derive:
• Mainly in order to achieve the desired bobbin form, a very
sophisticated drive system is necessary
• Mechanical derive system
• Electronic derive system
Winding Zone
• Lifter Motion:
• In the package, each turn must be laid next to its neighbors.
• For this purpose, the lay-on point must continually be moved.
• This can be brought about only by raising and lowering the
bobbins.
• This requirement cannot be met by raising and lowering
the flyers, because then the unsupported roving length
(from drafting arrangement to flyer top) would vary
correspondingly and the angle of departure from the
drafting arrangement and of approach to the flyer top
would change continuously.
Winding Zone
• The individual coils of the bobbin must be laid closely
adjacent to each other, not only in the first layer but also in
all subsequent layers
• The package diameter is steadily increasing, the lift speed
must be reduced by a small amount after each completed
layer
• The lift drive is also transmitted via the cone transmission
(as for the bobbin drive), but not via the differential.
• A reversing drive must be provided so that the bobbin rail is
alternately raised and lowered.
Winding Zone
• Cone Derive transmission:
• Variation of the bobbin rotation speed originates in the cone
transmission and occurs in small steps through shifting of the cone
belt after each lift stroke.
• Bobbin rotation must be changed in accordance with a linear
function.
 Differentiate the roles
of different types of
gears?
Task
Role shaft?
 • To obtain the desired linear variation function, the cone faces
Winding have been made hyperbolic.
• Convex on the upper driving cone and concave on the lower
zone driven cone. Hyperbolic cones are difficult to design.
 • Cone Derive transmission
• This mechanism keeps the surface speed of roving bobbin
constant during operation of simplex machine. Two cone
drums are used in this mechanism.
Winding zone • The diameter of cone drum at bottom end is kept 7.0
inches and at top end is kept 3.5 inches. The top cone drum
has positive drive. This is driven through a shaft.
Winding Zone
• The motion from top cone drum is transmitted to bottom cone with
the help of a transmission belt.
• This belt is kept on bigger diameter side on positively driven cone
drum. This belt is connected to the negatively driven cone driven and
is kept at smaller diameter side of cone drum.
Winding zone
• The concept:
• The diameter of roving bobbin increases regularly after completing
each layer, thus surface speed of bobbin increases.
• At the same time the transmission belt starts to shift from bigger
diameter to smaller diameter and the rotational speed of bobbin’s
spindle is reduced.
• This reduction of rotational speed of spindle keeps surface speed of
bobbin constant throughout the process. Thus this mechanism also
helps to maintain constant roving tension throughout the process.
 • Shifting of the belt is controlled by the ratchet wheel (on axle 10).
• In the course of each change-over operation (after each stroke), the
ratchet wheel is permitted to rotate by a half tooth.
Winding zone • By way of a gear train including change wheels and an eccentric, this
ratchet steps out the wire rope (1) and hence permits movement of
the belt guide (5) to the right
Winding zone
• If the movement of the belt does not correspond to the increase in
bobbin diameter, the change wheel or ratchet must be adjusted
accordingly
• Sometimes, the adjustment resulting from changing by one tooth
would have an over-large effect; a change by only half a tooth might
in fact be suitable.
Change Places at Roving frame
• For Drafting
• For Twisting
• For Winding
• Others
Change Places at Roving frame
• MAIN SHAFT DRIVE DISCS
• These drive discs provide the only opportunity to adjust spindle
rotation speed.
• INFEED CHANGE WHEEL
• This influences the tension in the slivers between the creel and the
infeed to the drafting arrangement.
• BREAK DRAFT WHEEL
• This enables the rotation speed of the middle cylinder to be changed,
thereby changing the break draft with simultaneous alteration of the
main draft. The break draft must be adapted to the material.
Change Places at Roving frame
• MAIN DRAFT WHEEL
• A change here results in simultaneous variation of the rotation speeds of
the middle and infeed cylinders. Since the rotation of delivery cylinder
remains unchanged, the main draft is altered, as is the total draft.
• TWIST WHEEL
• Replacement of this wheel results in a variation of all speeds, except that of
the flyers.
• Since the roving twist arises from the relationship between flyer rotation
and delivery speed, a change in twist level arises from adjustment here.
Change Places at Roving frame
• LIFT CHANGE WHEEL
• The lift speed of the bobbin rail is influenced by this element, and
hence the laying density of roving coils on the bobbin.
• A wheel should be chosen such that the coils of the first layer lie close
to each other and practically hide the tube.
• The coils should also be arranged closely adjacent, but not on top of
each other. In this way, the bobbin is made to take up a lot of
material.
Change Places at Roving frame
• CONE DRUM CHANGE WHEEL
• If the diameter of the tube is altered, the starting speed of the bobbin
must be adjusted accordingly.
• Since the ratchet wheel has not been operated at this stage, the
adjustment cannot be made by means of the builder motion.
• The starting position of the cone belt can be changed or, when this is
no longer possible, another cone change wheel can be substituted.
Change Places at Roving frame
• RATCHET CHANGE WHEEL
• This determines the amount by which the belt is shifted at each
operation of the ratchet and therefore must be adjusted precisely to
the increase in bobbin diameter.
 Electronic Drive System
Servo motor is made up of DC motor which is
controlled by a variable resistor
Electronic Drive System
• Electronic devices such as frequency converters and individual
servomotors have enabled the drive system of the roving frame to be
considerably simplified
• Spindles and flyers are driven directly by individual servomotors.
• The control system ensures synchronized running throughout package
buildup
• Such drive systems are not only much simpler than mechanical drive
versions, but also have additional advantages such as lower energy
consumption and reduced maintenance.