Simplex

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Function /objectives:
The chief function of roving frame is the
attenuation of sliver.
Insertion of protective twist in order to hold the
fine strand of sliver.
Winding of roving into a package that can be
transported, sorted, donned on ring spinning
machine.

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Necessity of Roving Frame:
There are two principle reasons:
First reason is to apply drafting.
 Sliver is thick, untwisted strand that tends to be hairy and to
create fly. Therefore, if we directly want to produce yarn from
sliver by discarding simplex, we need 300 to 500 drafts to do
so. But the fine twisted roving is significantly better suited to
this purpose.
 Second reason is related with transportation and space
limitation on ring frame.
 Draw frame "can" is the worst conceivable mode of
transportation and presentation of feed material. 3
Operating region of Roving frame:
The creel
The drafting arrangement
• Roller drafting system
• The apron
• Applying pressure to the top roller.
• The condenser
• The spacer
Winding of bobbin
• Package build
• Bobbin drive
Cone drive transmission
The lifter motion
The builder motion
Spindle & flyer
• Imparting twist
• Spindle
• Flyer
• Design of flyer
• Pressure arm
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Creel:
• Creel is used to guide the sliver. creel portion is present
above the can.
• Creel help the sliver on their way to the drafting
arrangements without any disturbance

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Guide roller:
•Guide roller is used to guide the sliver.

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Sliver guide:
•These are also used to guide the sliver.

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Condenser:
•Condenser is used to condensing/pressing the sliver.
•The purpose of condenser is to bring the fiber strand back together again.

Feature:
•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.

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Pressure arm:
•Pressure arm is use to give pressure onto the material.

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Cradle:
•Cradle is used to give proper tension to the upper and bottom
rollers for proper guidance of material.

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Drafting arrangement of roving frame:
•Roller drafting system
•Conventional roller drafting system:
•4 over 4 without apron.
Modern Roller drafting system:
•3 over 3 drafting system with double apron (Lakshmi
Rieter FS185P)
•4 over 4 drafting system with double apron (SKF PK 1600)

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SKF PK-1600 drafting system:

•Draft range: Total draft 5 to 20

•Total draft is distributed in each zone as follows:
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Back zone:
•Break draft is applicable in here. Amount of break draft
is depends upon material.

Material Break Draft

Sliver Coarse 1.5-1.4

Sliver Medium 1.4-1.3

Sliver Fine 1.3-1.2

Sliver MMF 1.2-1.1

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Middle zone:
•Less amount draft is applicable in here.
•Condenser is used in middle zone to condense sheet like sliver.
Front zone:
•Maximum amount of draft is applicable in here. Apron is used in
this zone.

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Roller type:
•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.
Roller dia:
Roller 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

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 Apron:
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 guide and transports the fibers during
drafting and they exert a very significant influence on the drafting operations.
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 Applying pressure to the top roller:

•The top roller must be pressed with relatively high force

against the lower rollers to ensure the guidance of fiber.
•Pressure is 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
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•Spacer:
•As the top apron is forced by spring pressure against the lower
apron, the arrangement of this apron should permit precise
adoption of minimum distance to fiber volume. In order to be
able to maintain this minimum distance, spacer are replace ably
inserted between the nose bar of the lower apron and the cradle
edge of top apron. Spacer size is 4 to 7 mm in accordance with
roving hank.

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Rubber cot:
•Cots are made of rubber or synthetic material and are mounted on top rollers

Top cloth roller:

•It is used to clean the rubber cot rollers.

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 The flyer:
•Flyer is a machine part of speed frame, made of steel & is
used for roving winding t he w legs. Flyer is placed on spindle &
it gets motion by gearing
•Flyer can be varying in sizes which are specified in inch. For
example, 12" × 5.5", 12 × 6 and 14" × 6". First no. indicates
maximum height and second no. indicate maximum dia of wound
package.

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Objects of flyer:
•Flyer is used to impart twist. It gives one twist per
revolution.
•Flyer has two legs, one with hollow path or slot for guide the
roving in proper place of the bobbin and another is pressure
arm for balancing the flyer while rotating & helps to produce
a compact bobbin.
•Flyer speed has direct influence on production.

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Pressure arm of flyer:
The arm has to guide the roving from the exit of the flyer leg to the package

Roving rail:
•Roving rail moves up and down to wind the roving on the bobbin.

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 Roving bobbins:

Winding Principle:
•Bobbin leading principle (For cotton spinning)
•Flyer leading principle (For jute spinning)

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Bobbin leading Principle
•Bobbin speed is higher than flyer speed
at all point of winding.
•The winding on speed is constant
throughout the process.
•With the increase of bobbin dia bobbin
speed must be decreased.
•The variation of bobbin speed with the
increase of bobbin dia must be constant.
•Less tension on roving.

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Mathematical relation:
Let,
Front roller delivery = L inches/min
Spindle speed = Ns rpm
Bobbin speed = NB rpm

Bobbin dia at any instant = d inch

So, bobbin circumference = πd
Winding on speed = (NB- Ns)

Total winding length = πd(NB- Ns)

L= πd(NB- Ns)

If L, π, Ns fixed, when “d" increase then N B decrease.

So with increase bobbin diameter, bobbin speed gradually decrease.

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Flyer Leading Principle
•Flyer speed is higher than bobbin speed at
all point of winding.
•The winding on speed is constant
throughout the process.
•With the increase of bobbin dia, bobbin
speed must be increased.
•The variation of bobbin speed with the
increase of bobbin dia must be constant.
•Higher tension on roving.
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Mathematical relation:
Let,
Front roller delivery =L inches/min
Spindle speed= Ns rpm
Bobbin speed = NB rpm

Bobbin dia at any instant= “d” inches

So, bobbin circumference = πd
Winding on speed = (NS- NB)

Total winding length = πd(NS- NB)

L= πd(NS- NB)

If L, π, Ns fixed, when “d" increase then N B increase.

So with increase bobbin diameter, bobbin speed gradually increases.

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Recent Development of Speed Frame
1.Improved drafting system: Modern drafting system like SKF PK 1600, SKF
PK 5000 etc give more controlling fiber and they able to import 8 to 20 draft on
sliver.
2.Higher flyer speed: Modern flyer speed is more than 1000 rpm where as the
convention flyer reaches maximum 600 rpm.
3.Plastic flyer: lighter in weight and less power consumption in results
4.Flyer driving from top: Modern flyers are top mounted and having no spindle
which in following issues:
• Auto doffing operation
• Reduced flyer leg spreading
• Higher flyer speed

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5. Inching motion: It initiates flyer turning slowly for piecing if the end breaks.
And also tension on roving while the machine starts.
6. Auto stop motion: Various auto stop motions are initiates to reduce waste
and increase efficiency Sliver stop motion, Roving stop motion, Creel stop
motion, full bobbin stop motion, Doffing stop motion.
7. Pre determine set length: Machine stops automatically after a
predetermined length of roving is wound on bobbin.
8. Monitoring system: Modern speed frame includes data monitoring system
by direct reading of production, efficiency, speed of flyer, stoppage time,
quality monitoring and package built.
9. Auto doffing: Like some ring spinning machine, simplex machine
manufacturers offer the machine having automatic doffing system where full
bobbins are replaced by empty bobbin without any help of worker.
10. Automatic tension controller: it determines the tension on roving
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continuously and send data to inverter to adjust its peed.
Faults in speed frame:
Irregular roving
• Irregular draft
• Top roller dia variation
• Pressure variation.
• Rough surface of apron
• Improper roller setting
Roving Breakage:
• Irregular roving
• Tension variation
• Variation of pressure on top roller
Sloughing off:
• Improper taper end
• Faulty taper wheel 30
Roller lapping:
• Stickiness formation on roller
• Wet roller surface
• Excessive dry roller surface
• Dust deposit on roller.
Unequal tapering:
• Wrong angle of poker rod
• Different lifting and lowering distance due to faulty builder
motion

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Soft bobbin:
• Winding on speed is less than front roller delivery
• Less tension on roving during winding
• Less coil/inch (if top rail speed is too high it results
excessive spacing between adjacent coil.)

Dirty roving bobbin:

• Excessive oiling on machine parts
• Insufficient machine cleaning
• Cracked bobbin and careless handling
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Factors considered for roller pressure:
1.Bulk of material: For coarser fiber less amount of pressure is
needed.
2.Amount of draft: For higher draft, roller pressure will be
high.
3.Type of fiber: Cotton is a soft fiber, as a result it requires
higher amount of roller pressure. Polyester requires less.

Typical value of roller pressure:

Roller PK-1600 PK-1500

Front 20-30 dn 9-15 dn
2nd 15-20 dn 15-25 dn
3rd 10-15 dn 10-20 dn
Back 10 dn 10-20 dn
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Factors considered for Roller distance:
1.Bulk of the material: Higher the bulkness of material, roller setting
should be wider.
2.Amount of draft: For higher draft roller distance should be higher.
3.Staple length: For higher staple length distance should be higher. The
rollers have to set at such a distance that the drafting takes place
smoothly & evenly without producing any sort of unevenness or
irregularity.

Drafting zone Roller distance

Front Effective length+ 1/16~1/8 inch
Middle Effective length+ 1/8~3/16 inch
Back Effective length+ 1/4~5/16 inch
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Advantages of Apron drafting over roller drafting:
1.Better control of short fiber movement.
2.Higher range of draft.
3.Wide range of staple length can be processed in one setting.
4.Lower end breakage & roller lapping. 5. Higher spindle
speed.
5.Higher production.

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Factors consider for selection of twist in roving:
1.Staple length of fiber: For higher staple length, twist per unit
length is lower, because in long fiber lower twist results
sufficient strength.
2.Hank of the roving: For higher hank, TPI increase.
3.Fineness of the fiber: For finer fiber, TPI should decrease.
4.Type of the material: Depends on fiber strength, different
fibers require different twist.eg. Cotton fibers require higher
twist where polyester requires less twist.

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Twist multiplyer:
Twist multiplyer (TM) defines twist angle tan0. The value of
twist factor indicates the degree of twist in a fiber strand; a
higher value indicates hard twist & a low value soft.

Roving hank TM
0.8-1 1.3
1-1.2 (Coarse yarn upto 40s) 1.2
1.3-1.5 1-1
1.5-2 1
2-4 0.9 37
Bobbin building process:
Roving is wound on bobbin in conical shape. The conical shape bobbin
can be produced in 3 ways.
1.Roving building process: Here the traverse length is gradually reduced
as the bobbin is build up. When the bobbin is empty, full traverse length is
used & then it is reduced gradually.
2.Cop building process: Here the traverse length is fixed & shorter than
roving building. Lifting of bobbin is done so that traverse length is shifted
along the bobbin length. It is used in Ring frame.
3.Combined building process: Here the traverse length is larger than that
of cop but shorter than that of roving building. It is the combination of
roving building & cop building. Traverse length is always fixed.
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Relationship between cone drum diameter & bobbin
diameter: Or, Cone drums profile:
Let, Front roller delivery = L cm/min
Top cone drum diameter = DT cm at any instant

Bottom cone drum diameter = DB cm at any instant

Bobbin diameter = B cm
If top cone drum speed =R
Bottom cone drum speed = R × DT/ DB
If value of gear train from the bottom cone drum to the winding
speed = K1
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So, Winding on speed = Nw = R × DT/ DB × K1
Since front roller delivery = L cm/min
So it is said, Nw = L/πB
So, Nw = R × DT/ DB × K1 = L/πB

DT/ DB = L/πB R K1

DT/ DB = K/B [where K = L/πR K1= constant]....................(i)

For belt drive, diameter of any two place of cone drum must be constant.
Let, DT + DB = 26 cm [Constant]

Empty bobbin diameter = 3.35 cm

Initial top cone drum diameter, DT = 16.86 cm

So, DB = 26-16.86 = 9.14 cm

From the equation no. (i) DT/ DB = K/B

K = DT × B/DB
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Again, putting the value of K at equation no.(i) we get,
DT/DB = 6.18/B

DT = 6.18 × DB/B

DT = 6.18 × (26 -DT)/B ................(ii)

DB = DT × B/6.18

DB = B × (26 –DB)/ 6.18 ...............(iii)

If the bobbin diameter of 1st layer = 3.35+0.65 = 4 cm

So, for 1st layer,
DT1 =15.784cm

DB1 = 10.246cm

Figure
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Draft change pinion (DCP):
•The amount of draft is changed by D.C.P.
•In speed frame, D.C.P is in driver position & it controls the speed of back roller.
•If D.C.P is larger in size then back roller speed increases & more material is feed.
•The speed of front roller remains same; as a result draft will reduce. Because
Draft = Front roller speed / Back roller speed
So, D.C.P Draft Roving hank
Draft α1/D.C.P
Draft = K. 1/D.C.P
Draft × D.C.P = K = Draft constant
D.C.P = Draft constant / Draft
D.C.P1/D.C.P2 = Draft 2/ Draft1

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Draft constant change pinion (D.C.C.P):
•Draft constant is changed by changing D.C.C.P. .
•If D.C.C.P is larger in size , then draft constant increases &
vice-versa.
•When D.C.P of required teeth is not obtained then D.C.C.P is
used to change.
Twist change pinion (T.C.P):
•TPI is change by changing T.C.P.
•If T.C.P is larger in size, then front roller delivery & bobbin
speed increases. As a result TPI decrease, because

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 TPIα1/T.C.P
TPI = K.1/ T.C.P
TPI × T.C.P = K = Twist constant
T.C.P = Twist constant /TPI
T.C.P1 /T.C.P2 = TPI1 / TPI2

Again,

So, If TPI more than hank more.

•T.C.P creates no effect on draft, because T.C.P keeps front roller speed
& back roller speed ratio same.

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Twist constant change pinion (T.C.C.P):
•T.C.C.P is used to change twist constant.
•Twist constant increases with increasing T.C.C.P & vice-versa.
Lifter change pinion (L.C.P):
•L.C.P determines coils/inch of roving on to the bobbin.
•Coils/inch is related with roving hank.
• When roving hank more, then coils/inch will be more, because
more roving hank causes less diameter of roving
•So it requires less rate of lift of bobbin rail
•Rate of lift of bobbin rail is determine by L.C.P
• If L.C.P is larger in size, then rate of lift will be more &
ultimately it will se les coils/inch. 45
So,
L.C.Pα1/ coils per inch

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Ratchet wheel (R.W):
•Ratchet wheel is directly related with roving hank,, bobbin diameter,
bobbin speed & belt movement
•We know, ratchet wheel makes a teeth movement after competition of
winding one layer of roving on to bobbin. .
•Again, after winding one layer of roving, the cone-drum belt is moved
depending on the bobbin diameter.
•For finer count roving i.e when roving hank is more than cone drum belt
is moved less after winding one layer of roving which causes teeth
movement of ratchet wheel.
So, as the circumference of the ratchet wheel is fixed, the pitch of ratchet
will be small. As a result, no. of teeth of ratchet wheel will be high.

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Spindle speed change pinion (S.S.C.P):
•In speed frame, S.S.C.P is in driven position.
•So, increase in S.S.C.P will cause decrease of main shaft speed.
•Spindle gets drive from main shaft; so spindle speed will be less
due to decrease of main shaft speed.
So, spindle speed a 1/S.S.C.P
Again,
Production or front roller delivery in inches/min = Spindle
rpm/TPI

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Tapper wheel (TW):
Figure
•Tapper wheel is used to produce tapper end shape or
conical shape of wound yan on to bobbin.
•Tapering occurs due to decrease of the length of the
pooker rod.
•If Tapper wheel speed more or tapper wheel is large in
size then poker rod will move fast & length of poker rod
will be decrease quickly.
•It will result more taper end.
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Important process parameters in simplex:
1.Feed hank
2.Delivery hank
3.Roving tension
4.Break draft
5.Type of drafting
6.Bottom roller setting
7.Top roller setting
8.Spacers
9.TM
10.End breakages rate 50
Wastages in Simplex/Speed Frame:
1.Sliver
2.Roller Waste/Bonda
3.Pneumaphil Waste
4.Roving Waste
5.Sweeping Waste
6.Clearer waste
7.Invisible Waste
Note: Above 0.50% of total amount of wastage is not acceptable

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Wastage Reduction Procedure/ Factors for Wastage Reductions:
1.Acceptable Raw materials selection
2.Spindle speed within acceptable range
3.Accurate Rollers Setting
4.Proper Twist insertion
5.Well Machinery condition
6.RH% and Temperature within satisfactory range
7.Proper material handling
8.Adequate supervision

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Function of building mechanism:
1.Make the taper shape of the bobbin. (Coning motion)
2.To transfer the cone drum belt. (Reduction motion)
3.Change the direction of bobbin rail. (Reversing motion)

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•Make the taper shape of the bobbin. (Coning motion):
There is a slide fixed in the bobbin rail. A groove is present in the slide
where poker bar is accommodated. The slide moves up & down with the
movement of bobbin rail. At one end poker bar is threaded. Taper wheel
becomes meshed with threaded part of poker bar. This taper wheel & end
portion of poker bar is accommodated in the top cradle. Toper cradle
moves in the direction shown in the figure. Movement of it may be
decreased or increased by moving the setting screw to inner side, or on
the edge of top cradle. There are two pigeon catch’s which are attached
with coil spring become meshed with the profile when necessary.

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•Make the taper shape of the bobbin. (Coning motion):
As the slide moves up. & attain a position shown in figure. In this
position left pigeon will be displaced from the profile. And right pegion
catch is going too meshed with the profile. In this case length of pocker
bar shortens in one teeth. When bobbin rail going to move downward then
the right pigeon catch is displaced & left one is going to attached with the
profile. Another teeth now goes & as a result poker bar length becomes
shorten. This change will continue until required conical shape of bobbin
is achieved i.e. up to certain limit. The poker bar length will be shortening
up to 5 inch of poker bar.
During every change in the building motion the taper wheel rotates at
each change & shortens the length of the poker bar as a result the lift of
the bobbin is shortened & gives bobbin a conical shape.
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• To transfer the cone drum belt. (Reduction motion):
When left pigeon catch is going detach from the profile then hammer hits
the mashroom catch (right) as a result the right mushroom catch
disconnects from gear & as the right & left mashroom catch is joined by
spring so that left one is meshed with ratchet wheel, during this period
ratchet wheel moves half of teeth by weight. Tapper wheel is connected in
a same shaft of ratchet wheel, so that it moves teeth. During this time of
operation up right shaft pinion moves left way & long rack is shortened by
teeth. Upright pinion in connected with bevel clock wise through upright
shaft.
A strap is connected with the long rack. So that by this diameter of cone
changes same result is happened if right pigeon catch is going to detach.
By this mechanism reduction motion is achieved. 56
• Change the direction of bobbin rail. (Reversing motion):
When the left pigeon catch is going to detach from the profile
then hammer which is connected with stroke rod hits the strike
rod. So that one part of no. 2 portion is attached with upper
part as per figure. No. 2 portion moves right to left or reverse.
Through gearing the motion transferred to the rack. Rack
determines to which position the material wound on in the up
& down portion of the bobbin. Same results will happened if
right pigeon catch is going detach & when one (a) part if
geared with the upper part.
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Draft at Speed frame:
In the machine we can observe three drafting zones.
1.Back zone (break draft)
2.Main zone (major/main draft)
3.Front zone (tension draft)

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i.Back zone (break draft):
Here the main objective of the break draft is to improve the fiber
orientation instead of drafting itself. In main draft the drafting
operation take place but for an optimum draft the fiber orientation is
very important factor. To achieve good draft fibers has to be
straightened and parallel, this is done by break draft. In roving frame,
draft level often has its over and upper levels/limits of drafting. The
drafting is done in between this limits, if not, each of the case tends to
transfer high masses through the nips. Always the break draft kept in
low level because it only improves the evenness of the sliver.

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Factors affect on break draft:
1. Volume of the material: More volume of the material requires more
preparation of the material and more will be the break draft
2. Type of the material i.e. cotton, polyester, PC, PV etc.
3. Moisture content: More the moisture content more will be the break
draft and vice versa 4.Roller setting: If rollers are close then we apply
more break draft
5. Fiber length: More the length of fiber more will be the break draft
and vice versa.
6. Blending ratio: If PC blends are, 65:35 & 52:48 then in 65:35 we
apply more B.D. In PV break draft is more as compared to PC.

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ii. Main draft:
Main draft is the drafting zone the real drafting is taken place. In
here a draft in high magnitude is taken place. For good fiber control
many methods are used such as aprons, pressure bars etc.
iii. Tension draft:
The main objective of the tension draft is to maintain better and
adequate tension to the sliver. In this zone actually the finer count
for the roving frame is already achieved but after freeing from front
roller nip twist has to be inserted, for this it's important to keep good
evenness throughout the sliver.
Total Draft = (Break draft) x (major draft) x (tension draft)

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Twisting:
"Binding of fiber strand by revolving it about its own axis is known as
twisting"
Twisting mechanism:
After drafting, material came out from the nip of the front roller and this form
of material is called roving. So one end is gripped between two roller's nip
and other end enters in flyer cap. This roving then passes through the flyer leg
and flyer presser. The insertion of the twist is done by the flyer when flyer
rotates the twist in sliver is achieved. Suppose 1 inch roving comes out from
front roller nip and flyer turns 1 revolution then it means that in one inch
roving, twist/turn is 1 i.e. TPI is 1.
Each flyer rotation creates one twist in roving. Twist per unit length depends
on the delivery rate of front roller.

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THANK YOU

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