Draw frame

• From a purely commercial viewpoint the

draw frame is of little significance
– it usually contributes less than 3% to the
production costs of the yarn.
• However, its influence on quality, especially
yarn evenness, is all the greater for this.
– if the draw frame is not properly
adjusted, yarn strength and elongation will
also be affected.
Drawing
• Drawing is the operation by which slivers are blended,
doubled and leveled.
• In short staple spinning, the term is only applied to the
process at a draw frame.
• In drawing slivers are elongated when passing through
a group of pair rollers, each pair is moving faster
than previous one.
• This permits combing, drawing and elongating of
several slivers to make them strong and uniform.
Drawing
Definition:
• Drawing is the term applied to the operation involving
the doubling and roller drafting of slivers.
Doubling
Definition:
• Doubling is the combination of several slivers that are
then attenuated by a draft equal in number to the slivers
combined, thereby resulting in one sliver of a similar
count.
Roller drafting
Definition:
• Roller drafting is the process of attenuating the count of
a material using a combination of pairs of rollers.
DRAFTING
The reduction of weight per yard of sliver and
increase in length is called drafting
OR
Attenuation of sliver without breaking is called
drafting
Total draft = Break Draft X Main Draft
Break Draft – Draft B/W second and third roller
Main Draft – Draft B/W second and front roller
Draft and Attenuation
• A carded sliver contains 20,000-40,000 fibres in cross-
section.
• In a yarn, the number of fibres in the cross section is
approximately 100.
• Therefore, while converting a sliver to a yarn, fibres must
be distributed over a greater length so that the cross
section is gradually reduced.
• This gradual reduction of the cross section is called
“attenuation” and happens because of extending fibre
strand to a longer length by slippage of fibres over one
another.
• Extension of the length is called drawing.
• The amount of extension of length is called draft.
Types of draft
1. Actual draft : the ratio between material feed
and delivered
Actual draft = length / count delivered / length /
count feed
2. Mechanical draft: the ratio between surface
speed of delivery rollers and surface speed of
feed rollers
Mechanical draft = surface speed of delivery
rollers / surface speed of feed rollers
Objects of drawing
1. To straighten the crimped, curled and hooked
fibers.
2. To make the fiber parallel to their neighbors.
3. To improve uniformity of fibers by drafting and
doubling.
4. To reduce weight per length unit of sliver.
5. To remove dust from slivers.
6. To blend raw material of same hank perfectly.
Necessity of Draw frame
• To parallelization of fiber and blending the
carded sliver, draw frame is needed.
• In carded sliver, fibers are present in hook form
i.e. trailing hooks and leading hooks.
• To parallel these hooks, draw frame is used.
• Majority of the fiber hooks in a carded sliver
are trailing hooks while leading hooks are
comparatively less.
• Trailing hooks are also known as major hooks,
while leading hooks are known as minor hooks.
Tasks of Draw frame

 Equalizing

 Parallelizing

 Blending

 Dust removal
Equalizing (doubling):
• One of the main tasks of draw frame is improving
evenness over short, medium and especially long terms.
• Carded slivers are fed to the draw frame have degree on
unevenness that cannot be tolerated in practice and
slivers from the comber contain the “infamous” piecing.
It is obscured by draw frame.
• Equalizing is always performed by a first process,
namely doubling and can optionally also be performed
by a second process, namely auto leveling.
• The draft and the doubling have the same value and lie
in the range of 6 to 8.
Parallelizing:
To obtain an optional value for strength in the yarn
characteristics, the fibers must be arranged parallel in
the fiber strand.
The draw frame has the tasks of creating this parallel
arrangement.
It fulfills the task by way of the draft, since every
drafting step leads to straightening the fibers.
• The value of the draft must be adapted to the material,
i.e. to several fiber parameters, mainly:
– the staple length;
– the mass of the fibers;
– the volume of the strand;
– the degree of order (parallel disposition).
• It will be clear that the draft cannot be high on a
machine directly following the card (if possible, not
above 8), but thereafter can increase from machine to
machine.
Blending:
In addition to the equalizing effect, doubling also
provides a degree of compensation of raw material
variation by blending.
Their results are exploited in particular way in the
production of blended yarns comprising cotton or
synthetic blends.
At the draw frame metering of the individual
components can be carried out very simply be selection
of the number of slivers entering the machines.
Dust Removal:
• Dust is steadily becoming a greater problem both in
processing and for the personnel involved.
• It is therefore important to remove dust to the greatest
practical extent at every possible point within the overall
process.
• Dust removal can only be carried out to a significant
when there are high levels of fiber.
• Since a large function the smallest particles adhere
relatively strong to the fibers.
• High performance draw frame is equipped with
appropriate suction removal systems; more than 80% of
the incoming dust is extracted.
Actions involved in Draw Frame
• Drafting: It is the process of increasing length per
unit weight of sliver. It is mainly due to peripheral
speed of the rollers.
• Doubling: The process of combining two or more
carded sliver into a single form is called doubling.
In draw frame m/c generally six slivers are fed to
convert into one i.e. six doubling.
• Drawing: In the cotton industry the term is applied
exclusively to processing on the draw frame, where
the operation is one of doubling and drafting.
Drawing= Drafting + Doubling.
PRINCIPLES OF DOUBLING
• This involves placing several slivers in parallel
(usually 6 or 8) and roller drafting the combination
using a draft equal to the number of juxtaposed slivers.
Doubling serves two purposes.
• The reduction of sliver irregularity
• Improves the blend or mix of the fibers.
• In general terms, the number of doublings is given by
the expression SR
• Where S is the number of juxtaposed slivers and
• R is the number of repeats.
• Theoretically, the limiting value of R will be where no
further reduction in the irregularity can be obtained.
• In practice R = 2 or 3 is usually accepted as sufficient.
• The measured sliver counts are based on 1- to 5-m
lengths.
THE DRAWING OPERATIONS
• The drawing operations are primarily concerned with
converting card slivers into drawn slivers in which
fibers have been straightened and aligned with a high
degree of parallelism.
• It is essential that the short-, medium-, and long-term
irregularities of drawn slivers are as low as possible,
with no periodic variation present.
• Effective control of floating fibers can be achieved by
increasing the interfiber friction.
• Although it is possible to apply suitable additives to
fibers to increase this friction, the preferred alternative
is to do so mechanically, as this is a simpler
Elements of the draw frame
i. creel (sliver feed)
• The creel is used to feed the material to the
drafting section without false draft by rotatable
roller or roller pair provided above each can, one
for each sliver. Creels are made of high precision
cast aluminum. The creel must be designed:
• To avoid false drafts
• To stop the machine upon a sliver breakage and
• To deal sliver breaks easily, comfortably and
safely.
The creel can be of:
• One or two rows
• Short creels for cans up to 600 mm diameter or
long creels for larger cans up to 1000 mm
diameter
• 6 fold or 8 fold doublings
• Automatic or manual can transfer (in most
cases, manual can transfer creels are used).
ii. The drafting system
• Drafting arrangement is the heart of a draw frame as it
exerts the most decisive influence on quality. The
drafting arrangement should be:
• Simple, uncomplicated construction
• Stable design for smooth running at high speeds
• Flexible to handle different types of fibres
• Able to control fibres properly to produce a uniform
sliver
• Easy to operate and adjust the settings
• Easy to maintain and clean
Elements of the drafting arrangements in short-
staple spinning are:
• Bottom rollers
• Top rollers and
• Fiber guiding devices.
Bottom rollers
• In all drafting arrangements, bottom rollers are
made of steel and mounted in roller, ball or needle
bearings.
• They are positively driven.
• These rollers have one of the following types of
flutes to improve their ability to carry the fibers
along:
• Axial flutes
• Spiral (inclined) flutes
• Knurled flutes
Knurled flutes are used on rollers receiving aprons to
improve transfer of drive to the aprons. In draw frames,
spiral fluting is used mostly because:
• It offers more even clamping of the fibers and lower
noise levels in running
• Its draft defects are minimized in the subsequent
processes
• top rollers can roll on spiral fluted bottom rollers more
evenly with less jerking and therefore, spiral fluted
rollers are preferred for high speed operation.
The diameter of the bottom
rollers in draw frames lies in
the range 20-90 mm, but
normally diameters between
25 and 50 mm are used.
The drafting arrangement
may include 3 – 6 bottom
rollers.
Distances between rollers of
the drafting arrangement are
adjustable and are adapted
to fiber lengths.
Top rollers
• Top rollers can be one-piece rollers (draw frames) or
twin rollers (roving and ring frames).
• Top rollers are coated with synthetic rubber.
Hardness of this coating is specified in terms of degree
shore.
• They are characterized as follows:
• Soft: 600-700 shore
• Medium: 700-900 shore
• Hard: Above 900 shore
• Soft coats surround the fiber strand to a greater extent
than harder ones and thus guide the fiber better, but wear
out more quickly.
• A soft coating is therefore used where good guidance is
necessary, i.e. where few fibers have to be moved with
high draft levels (e.g. at the front rollers of the ring
spinning machines). Otherwise, harder coatings are used.
• Ball bearings are used most exclusively in top roller
mountings.
• The top roller synthetic rubber is periodically ground
(called buffing) in order to maintain the roundness and
smoothness as the coatings wear out during spinning.
• The grinding operation has a roughening effect on roller
surface which leads to formation of laps when
processing sensitive fibers
For better smoothness after buffing, roller
coatings can be treated with:
• Applying a chemical film such as lacquer or
another smoothing medium
• Acid treatment
• Irradiation by UV-light
• To clamp the fibers, top rollers must be
forced at high pressure towards the bottom
rollers.
This pressure can be applied by:
• Dead weights (now obsolete)
• By spring weighting (more common)
• Pneumatic weighting (Rieter) – mostly used in
modern draw frames.
• Magnetic weighting (Saco Lowell)
• Hydraulic systems (hardly used)
Drafting system
• 3-over-4 roller drafting arrangement (Marzoli
draw frame):
• The characteristic feature of this arrangement is
the engagement of the middle pressure roller
with two bottom rollers.
• The two bottom rollers are carried in a common
cradle and are not adjustable relative to each
other.
• A pressure bar can further be included
inmaddition to this staggered arrangement.
Marzoli draw frame is an example.
 4-over-3 roller drafting arrangement with
pressure bar
• Strictly speaking, this is also a 3 roller pressure
bar drafting arrangement.
• A fourth roller with somewhat lower loading is
added to the delivery roller to act as a guide.
• This leads the drafted web directly in to
delivery trumpet.
FBR : 35 mm dia
SBR : 25 mm dia
TBR : 20 mm dia
FBR : 28 mm dia
BBR : 28 mm dia
TOP ROLLER : 40 mm dia
Roller Drafting Principle • A break draft zone (B):
• Drafting is mostly carried Draft (DB) = V2/V3
out by pairs of rollers. • A main draft zone (A):
• Fibres are firmly nipped Draft (DM) = V1/V2
between the bottom steel • Total Draft (DT) = V2/V3
rollers and pressured top X V1/V2
rollers.
• If the rollers are so rotated
that their peripheral speed
in the fibre flow direction
increases gradually, then
drafting takes place.
• The drafting arrangement
has two drafting zones,
namely,
Monitoring devices with autolevelling systems
• The objective of an autoleveller is to measure the
volume of fibers passing through (sliver thickness
variations) and then continuously alter the draft
accordingly so that more draft is applied to thick places
and less to thin places to deliver less irregular sliver than
it otherwise would have been.
• It is a online monitoring device in spinning process.
• It has become an integral part of the spinning process
for production of high quality yarn.
• It helps in achieving consistent count cv%.
Need of auto leveller
• To survive in this age of high competition, it has become
necessary to produce an internationally accepted
standard yarn quality.
• Carded slivers fed to draw frame to draw frame have
high degree of unevenness that cannot be tolerated.
• Comber contains infamous piecing.
• Higher CV% affects the appearance of dyed fabrics by
absorbing the dye unevenly.
Object of autoleveller
• To maintain consistent hank of sliver.
Principle:
• Adjust the Draft continuously, which will depend on
thickness of material fed.
• Autolevellers may be classified in to three main
groups according to the basic principle of operation:
Types
• Open-loop,
• Closed-loop and
• Combined-loop autolevellers.
Open-loop autolevellers
They compensate variations of short (to medium) wave length.
The solid lines indicate the flow of material through the
machine and broken lines represent the flow of information in
the autoleveller unit.
A measuring sensor is provided in the region of the infeed for
continuous detection of the actual value (volume)
mechanically, optically, pneumatically or capacitively.
A control unit compares the result with the set reference value
(related to the mean count of the material), amplifies the difference
signal and feeds it to an adjusting device (actuator or regulator unit)
which finally converts the impulse into a mechanical adjustment.
Therefore, control unit accordingly increases, decreases or leaves
unaltered the output of the regulator
Advantages:
• 1. It is easier to design than closed-loop autolevellers
• 2. It reduces short-term irregularities (variations)
Disadvantages:
• 1. It lacks self-monitoring, i.e. no check on the
delivered material by the control unit
• 2. It requires an additional element – the store
• 3. It cannot compensate for long-term variations
• 4. It requires very exact values of the adjustment at all
times
• e.g. Most autolevellers in worsted spinning processes.
Closed-loop autolevellers
• It is designed to correct medium-and long-term
variations.
• The principle of operation is illustrated in Fig. If the
direction of the arrows is followed from any starting
point, except the delivery, it always leads to a never
ending circuit of the loop which links the process and
the control unit, hence the name ‘closed-loop’
Advantages:
1. Simpler than open-loop control in operation as no store is
required
2. Self-monitoring, i.e. measurement always takes place on
the material after the point where corrective action is
applied. Therefore, the control unit continuously checks
the results of its action.
Disadvantages:
1. It is more complicated to design, especially to avoid
hunting, i.e. an unwanted oscillation in the out put
2. Dead-time inherent in the system. The measured portion
as long passed the adjusting point when the adjusting
signal arrives. Compensation of this measured portion
cannot be achieved; i.e. some f the long-and medium-term
errors with all of the short term errors remain in the
product.
Various parts of autoleveller
• Scanning roller
• Signal convertor
• Levelling processor
• Servo drive
• Quality monitor sensor
Advantages of autoleveller
• All variations are corrected.
• Count CV% will be consistent.
• Thin places in sliver and hence in the yarn
will be low.
• Higher efficiency in further processes.
Necessities of Auto stop motion
Stop motion is a device which provided to ensure
in the machine are stopped immediately if: –
1. The sliver run out from the creeled can.
2. Sliver brakes in the creel.
3. Lap up on drafting roller.
4. If sliver is chocked in the sliver collecting plate
and funnel.
5. If sliver is chocked in between trumpet and
calando roller.
6. If delivery can is filled with sliver.
If stop motion system is absent then the
following defects may arise:-
1. Considerable damage may cause to machine.
2. The output sliver may be thick or thin.
3. Lapping up of drafting or calendar roller.
4. Irregular drafting.
5. Excess of full can.
6. Too much waste produce.
7. The yarn strength or roving strength may
vary from place to place.
8. Any operator must have to attend the
machine full time to stop it at any fault.
Features of modern Draw
frame • Electronic control and
display unit.
Modern draw frame
manufactured by RETER • Improved drafting
have the following feature: system.
• High speed of production. • Can linking system.
• High draft. • Rectangular can.
• Better control of short • Fault locating induction
fiber. lamp.
• Auto leveling. • Monitoring system.
• Auto stop motion system. • Automatic can charger.
• Auto drafting and display • Suction system for
unit. drafting arrangement.