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ZENIT+
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FALCON-i
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Fax +41 43 488 11 03 wwwloep{e com
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SPIN CLINIC Spinning Knowtedge ENHANCER
On-line Quality Monitoring Systemsin SpinningMr, Sunil Kumar Sharma, Manager - QAD, PPC & Customer Care, Loknayak fayprakash Narayan Shetkari Sahakari Soot
Girni Ltd., MH
AbstractRapid changes in technology also chang-es every aspect of life. Technologicalchanges in industries not only changed
productiviry & qualiry but also changedwork culture too. Technological up-gradation of spinning machineries alsomakes easy operation, higher produc-tivity, user friendly maintenance andmore informative production update atany moment, online quality monitor-ing systems are part oftechnological up-gradation of spinning machineries. Allthe new generation spinning machiner-ies equipped with some special featuresof "0n-line Quality Monitoring" devises.Most of these devices are integral partof machinery, however some systemsavailable as optional attachment on extracost. Information provided by the on-linesystems may helpful, if it is properly pro-cessed and utilized in systematic manner.
The purpose of this article is to elabo-rate various online monitoring systemsavailable in modern spinning mills, sys-tematic process approach and utiliza-tion ofinformation obtained for effectivemonitoring, It's correlation with off-lineJaboratory test results and use of this in-formation for customer and others stackholder's references with full authenticity.
IntroductionProper & systematic utilization of "0n-line Quality Monitoring Systems" inspinning mills may improve productivity& quality level significantly.
Most of the new generation machineriesworks on electronically computer basesystems, this provide more & more onlineinformation for qualiry & productivity.Information obtained from on-line sys-tems is significantly differ with off-line or
78 | Spinning Textiles I Nov-Dec 2014
laboratory test results. Hence followingguideline should follow for processing ofon-line informationl
1. 0nline information may be moreaccurate for long term reports ascompare to shortterm report.
2. A co-relation factor should bederived by comparing the onlinedata w.xt. off-line or laboratorytest by comparing significant testsamples.
3, Itshould be co-related periodicallywith offline or laboratory test.
4. Online sensors should checkregularly for its accuracy andproper functioning. If require itshould be calibrated,
5, Atmospheric condition to bemonitor every time, when acquirethe on-line data.
On-line Monitoring Systems inSpinningFollowing "0n"line Monitoring Systems"are commonly used in spinning millsl
Cotton Contamination Sorter (CCS)Cotton contamination sorters are op-tional online quality monitoring devices,which detect & remove the foreign mat-ter from cotton. CCS provides informa-tion that how many foreign matter pointsdetected and removed by the systemsand recorded into system PC as "Eiection/ Minutes" or "Ejection/Hrsl'
These information may obtain as hourswise, day wise or rnonth wise, based onprogramming available with system PC,CCS is very important on-line monitoring
devices for contamination removal.Accuracy of CCS may observe by puttingcolour paper pieces of one sq, cm. eachinto b)Dw rcDm pjpe )jne )Dst befDre
CCS and see how much out of theme.iected through CCS. This shows the CCSefficiency for different colours. Cleaningof CCS glasses, cameras and light sourceand cotton path affect the performanceof CCS significantly, hence it should bemaintained properly and 0perationalinstructions should be followed strictly.
On-line Monitoring Systems at CardingStageAli the new generation carding machin-eries equipped with short term as wellas long term autoleveller function. Au-toleveller monitor the uniformity of feedmaterial as well as delivered materialand corrected whenever deviated fromdescribed value,
Production monitoring sensor placed ondelivery roll monitors the length of out-put sliver and calculate the production& machine efficiency, Following param-eters may obtain and monitored with^^- l i - ^ i * r^ - *^+^- . , .! 4 , u u , 5 , , , , u , , , , a r u ' ] .
. o/o Feed variation
. Cv o/o with different cut length
. A % deviation or actual sliver weight
. No. ofBreaks & its causes
Rieter Q-pack also provides followingadditional quality data:
. on-line mass spectrogram
. Slub/Thick places per km in sliverw.r.t. different diameter i.e. + 15 % to45 7o in the step of 5 % diameter
r ' a fi ' . * t , i *
This information may be recorded shiftwise or day wise for monitoring.
On-line systems for Br. DF's Unilap
/ Lap Formers & Combers & SPeedFramesNormally these machines are equippedwith production monitoring sensorsonly, hence only following informationmay be utilized:
. Machine & Production Efficiency
. Machine down times
. No. ofbreaks occurred
. Causes ofbreaks
On-line QualityMonitoringatRSB DF'sAfter carding, quality monitoring devisesplaced at RSB DFs only, where againautoleveller is functioning for betterevenness and control of linear density0i sliven 0n-line quality monitoringsystems at RSB DF's provides followinginformationi
. % Feed variation
. cv % with different cut length
. A o/o deviation or actual sliver weight
. On'line mass spectrogram
. Slub / Thick places per kilometer insliver wr,t, different diameter
According to quality requirements warn'ing & stop limit may set for differentquality parameters, Machine warninglights blinks, when any quality parametergoes beyond the setwarning limits, whilemachine stop immediately if any qualityparameters crosses the described stoplimit,
0n-line Monitoring SYstem at RingFrameOn-line monitoring systems available forRing fuames are optional attachmentsonly. This is very unique and importantsystem for measurement & monitoringof ring frame performance. System m0ni'tors quality & productiviry ofring framescontinuously round the clock. This sys-tem works in a combination of two differ-ent sensors located at different positionsat ring frames for monitoring the variousfunctions. These are Single spindle moni-toring [SSM) & production monitoring(PM). A travelling sensor performs theSingle spindle monitoring function while
B0 I SpinningTexti les L Nov'Dec 2014
production monitoring sensor placed onthe front delivery roll ofmachine.
i. Start up Breaks (STU): Breaksrecorded at the start of themachine after doffing within apreselected time.
ii. Normal Breaks (EB): Breaksrecorded after startup till doff isOVEI,
iii. Other Breaks (PRTI: Breaksother than STU & EB, normallyidle spindles,
100% Spinning
Setting of QMS at RSB DF's
RSB DF's are very sensitive machine for quality aspects. Hence the setting of
on-line quality parameters is a very precious mattex It should be very perfect &
accurate. Warning limit & stop limit ofsystems should be treated as 'Action Limit"
& "Control Limit".
Warning Limit = Action Limit
Stop Limit = Control Limit
For example if in a spinning mill allowable Fin DF sliver hanp 1;s11 15 +/- 2 0 %
and beyond this limit being treated as "Non-confirm product", then
. Warning limit should be set on +/- 1.50/0, where waming lights will blink for A
%o deviation.. Stop limit to be set at +/- 2.0 %0, where no production will allow beyond this
limit and machine will stop immediately.. Similarly warning & stop limits may be decided for CV %, Thick places &
Spectrogram,
. Momentary stops Positions (MsP):Momentary stops positions at anyinstance,
Travelling Sensor ' Idle spindles: Spindles which do not
One travelling sensor moves ftom produce anything for a "set of time"
one end to another end of dng fuame are listed as idle spindles Usually
and monitor the ring traveller motion spindles stopped for more than 30
and send the information to CPU. CPU Minutes are consideras idle spindles
processed the information received ' Rogue Spindles: Enables the user to
with traveling sensor and calculate the detect spindles which end breaks rate
following parameters: lies significantly above the machineaverage
. Ends Downi Ends down at any ' Worst Spinning Positions: This re'
instance obtain through systems PC port shows a maximum of 10 spindles. End Breaks Rate: No motion of ring with spindle number/ machine num-
traveller recorded as end breaks of ber with higher number ofbreaks'particular spindle position lt may ' Actual Spindle Speedr Rotational
obtain End breaks per 1000 spindles speed of each & every traveller is
Per hours for a particular ring frame measured by the travelling sensor
End breakages classified into three and the mean RPM of the machine
wDes i stored in system. TPM / TPh Twist per meter / twist
per lnch,. Slip Spindles 7or The individual
traveller speed is compared with the"Mean RPM" ofthe machine. A spindlewill be recorded as a slip spindle, ifit's traveller speed observed Iess thanthe limit set (i.e.3 - 5%) for morethan the number of times set.
Stationary Single Spindle MonitoringSystem
. End Mending Time (EM)r Mean Now days some machinery manufac-
duration of normal end breaks in tures also developed inbuilt stationary
minutes, This indicates operator single spindle monitoring sensors, which
efficiencv placed at each spindles.
SPII' iCLINIC
Production Monitoring SensorProduction monitoring sensor attachedat delivery roll of ring frames, monitorfront roll speed & after processed throughCPU following parameters calculated:
. Front Roll Speed: Actual front rolldelivery speed in RPM.
. DeliverySpeeds: Yarn delivery speedin meters per minutes calculatedfrom front roll speed,
. Total RingFrame production: Totalring frame production at any instanceand fo r a de f ined sh i f l durar ion inKg./Hrs or Kgs.
. cms per Spindle per Shift; Shiftwise GPSS f0r count-wise, group-wise& ring ftame wise.
. Total Down Times (STM): Totaldown time minutes since thebeginning ofthe shift.
. Efficiency: AEF 0/o i.e. Actual efficien-cy, PEF 0/o i.e. production efficiency,NEF o/o Now efficiency may getthrough system,
. No. of Doffs in a Shift: Total No. ofdoffs since the beginning of the shift.This report helps to monitor doffingload ofring frame doffers,
. Doffing Time (DFM): Total doffingtime in minutes since the beginningof rhe shift. This report heips to moni-tor ring frame doffing team efficiency.
Type of ReportsVarious types of reports may generatethrough system for analysis & monitonngpurposes. These are as follows:
Instantaneous Value ReportShows the status ofthe machine[sJ at themoment of call-up (i,e. instantaneousJ.No period is applicable f0r this reporr.
Shift Reports:Automatic shift report may obtained atthe end of shift with defined parameters.
Stoppage Reportsoverall analysis based on stop causespossible with or with0ut reference to memachine number. Reports may obtain inform of Stop summary stop history &stop diagram.
Long Term ReportsLong term reports for a fix interual r.e.
82 | Spinning Textiles I Nov-Dec 2014
on weekly basis or monthly basis mayobtained.
Article WiseIn this report machines processing thesame c0unt / material are l isted togethen
Operator / Supervisor Section WiseThis report provided an overyiew of themachine data as per work assignmentallotted to operator / supervisor section.
Group ReportAny number of machines can be puttogether into as many groups as possible.
On-line Monitoring System at WindingSpinning winding system is totallyequipped with online quality & produc-tion monitoring systerns. This works veryeffective and replaced traditional off-linemonitoring system,
There are two type of monitoring sys-tems that works at autoconer controlpanel. These both system works indepen-dently f0r quality & producti0n monitor,ing and exchange their information wlmeach othen These are:
. Electronic yarn clearer for qualitymonitoring
. Autoconer M.l,C. systems works forproduction monitoring
Electronic Yarn ClearerElectronic yarn clearers are the most ef-fective on-line quality monitoring tool inspinning, It is not oniy monitoring theyarn defects but also removes objection-able defects and improves the yarn qual-ity lt's measure the various yarn defectsvery preciously and classifu. Followingparameters may be monitored throughelectronic yarn clearers:
I. Classi[ication of seldom occurringyarn defects
GATEWAY to Spinning Industry
Auloconer In fo rmatorLatest autoconer systems providedetd i l on l ine in [o rmat ion fo r runn ingproduction as follows;
1. Single Drum or Machine produchon
at any Instance2. Machine & Production Efficiency3. Cause w ise producr ion Down T imes:
Detail causes wise productiondown time available with autoconersystems in duratjon and in percentageoftotal iosses as below:
. Red Light: Drums stopped due tooperational or mechanical failure
. Yellow Lightr Drum stopped forpackage doffing
. Recycling or Repearers Cycles:Repeater cycling for splicing
. Splice Failure: No. of splicefailures
. Bobbin Change Cycles: No. ofbobbin changes
. Rejected Bobbinsr No. of rejectedbobbins
. Clearer cuts per 100 km. ofyarn
. Clearer cuts per kg. ofYarn
. Clearer cuts per Bobbin
. Tension Breaks
. Yarn Breaks I i,e. Clearer cuts +Tension Breaks + Stop Cuts
. Total Yarn Joints
Most o[ above information may obtain intheir specified units or in percentage.
Responsibility for 0n-lineMonitoring SystemsAllthe on-line monitoring systems eitheravailable as an integral paft of machineor 0ptional retrofit attachments are veryexpensive pdrts which should be properlyutilized for its purpose & in favour oforganization, Usually responsibility ofon-line monitoring systems is not clearin spinning mills, which Iead ignorance ofthese multifuncti0n important systems.Hence responsibil i ty [or "on-lineMonitoring Systems" may be distributedas below:
All Quality Monitoring SystemQuality control / Assurance departmentis responsible to utilized all theinformation produced by 0n-line quairLymonitoring systems such as cotton
2.3 .4.
Periodic defectsClassification of foreign matterClassification of yarn joints & itsquallry
5. Detection of count variation6. Winding defects7. Online yarn imperfectionB, Alarms due to bad quality or off
standard cops
: ' ir;r ' l CLINIC
contamination sorters, different Cv's,
A% Lleviation, spectrogram analysis &
rh ick p laces mon i fo r ing Ih rough card ing
& RSB DFs, end breaks mon i to r ing in
throughout processes, Electronic yarn
c learer cu ts , c lass i [ i ca t ion & on l ine
lmperfection report fuom autoconer etc'
All Production Monitoring Systems
All production monit0ring reports should
be utilized by production supervisor for
their reference as instance production
figures, causes of detention and quality
deviafion etc. Shift wise - Machine wise
summary report should be PrePared
with all relevant information and should
be presented to sp inn ing master o r sp in -
ning manager for defail analysis & acfion
Machine operators may also educate to
read the production efficiency & down
tlme report
Maintenance Activities with the Help
ofOn-line SYstems
Main tenance dc t iv i t ies may synchron ize
with on-line reports Maintenance team
shou ld cont inuous ly mon i io r Cause w ise
breaks ofvarious pr0cesses and efficien-
cy losses due to mechanical faiiures'
Shift wise report may helps maintenance
manager for planning of preventive
maintenance activity.
Advan l ages o f 0n- l ine Mon i to r ing
Systems. Quick & instance report at any
moment for quality & Productivity
Performance.. Monitoring of whole Production
quantiw assure 100 %o qualitY
control.. As sample size is too iarge hence more
reliable & accurate measurement. Quality stops ensure that no defective
qualitY will be Produced. Easy for monitoring, anybody can see
results at anY time.. May get better quality & production
by educating machine oPerators'
. Bytaking proper monitoring & taking
timely appropriate corrective actions
machine down times may reduce
significantly. Significantly reduce calculation &
SPINNING SPECIFIC Magazine
clerical job of technical person, also
reduce load of quaiity control team
. Dependences on human and human
errors avoided.. Large scale data storage for future
reference maY be Possible
ConclusionTechnological up gradation introduced
idst, accurate and instdnce online m0n i-
to r ing sys iems some on- l ine mon i to r ing
systems available wilh spinning machin'
eries are integral part of machines and
some available at optional retr0fitattach-
ment. Accuracy and authenticity of on-
line sysrems should be check periodical-
ly. Cotton contamination sorters, carctlng
& RSB DF's & winding electronic Yarn
clearers systems works as effective qual-
ity m0nitoring tools, while single spindle
moniTor ing & produc t ion mon i to r ing ar
ring frame and windings provide lot of
information related to each position for
quality & production Properly & system-
atic utilization of On-line monitoring pro-
vide significant improvement in quality
& productivity with reduction in mont-
toring cost.
o1 c - , - - i - - T . - r i la< L Nnv-Dec 2014
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