FIELD OF INVENTION:

The invention relates to device for power consumption reduction in ring frame/spinning. The present invention is developed to save power required to remove/suck the broken thread or yarn end fibrous fleece on ring frame/spinning.

BACKGROUND OF INVENTION:

The textile industry consumes a large quantity of electrical energy & the demand for electricity is increasing, it has gone up to 18% nowadays which was 12% of the manufacturing cost in the year 2003. The textile industry retains a record of lowest efficiency in energy utilization and is one of the major energy consuming industries with about 34% energy consumption in the spinning process. Textile spinning mills energy audit indicates that the final machine i.e. Ring Frame/spinning (Ref. FIG 5), Ref numeral (500) in the spinning process for manufacturing yam consumes around 50-55% of the total consumption of electrical power. Cutting energy losses reflects lean manufacturing practices minimizing wastage s and is one of the ways that the mill can reduce power costs.

During the process of ring spinning having plurality of production centres ranging thousands of units per machine (normally 1.6 meters to 67-70 meters length of machine for 48-1824 units) where suction is generated by single or double suction fan fitted on machine on either side or in center to suck the broken thread or yarn end of fibres. Many times thread or yam break occurs due to various reasons including excessive tension on material during spinning so thread or yarn is considered as one of integral part of process and hence to continue process without hindrance as well as to remove broken end of fibrous lengths, the suction is commonly used.

On the existing conventional ring spinning systems such as ring frame & roving frame, irrespective of yarn & roving break, air is continuously sucked through the suction tubes. To generate continuous sufficient suction through all the suction tubes to suck the broken end of fibrous lengths, heavy power is required. On the existing conventional ring spinning systems, suction fan fitted on machine on either side or in center results in suction variation from source of suction generation to the other end to suck the broken thread end of fibres.

Due to continuous suction process the surrounding cool air supplied by the air- conditioning units is also wasted which again increases power consumption by the air-conditioning units.

The present invention is developed for overcoming the problems related with prior ring frame/spinning machines. Present invention provides cost effective solution to the problems as mentioned above.

SUMMARY OF INVENTION:

The present invention relates to device for power consumption reduction in ring frame/spinning which is efficient and low cost. The present invention consists of a one or more suction assembly (s) (100), suction head (101), a threaded holder (102), an impeller assembly (103), an impeller fan (104), a motor (105) and a sensor box (208).

A device for power consumption reduction in ring frame machine comprising of: a) One or more suction assembly(s) (100) being placed within a duct (110) having: a suction head (101) connected to a threaded holder (102) which is fixed on an impeller assembly (103) for suction of broken thread or yarn (400) during manufacturing in the ring frame machine and; a threaded holder (102) for attachment & mounting of suction head (101) at one end and attachment of holding impeller assembly (103) at another end; an impeller assembly (103) consisting of an impeller fan (104) placed on impeller base (103’) and enclosed by an impeller cover (103”); and a motor (105) for powering the impeller fan (103.), b) One or more Optical sensor assembly(s) (200) being placed in contact with suction assembly (100) having: an PCB circuit (201) consisting of IR transmitter (202) and receiver (203) for transmission and reception of IR signals in the path of roving thread coming from drafting front pair of rollers delivery for co-relating it with the presence or absence of the thread or yam (400) and sending positive or negative feedback respectively to MOSFET (204); Presence of thread or yam refers to yam is not broken and absence of thread or yarn refers to yarn is broken. a MOSFET (204) for driving the motor (105) of suction assembly (100) upon receipt of negative feedback from the IR transmitter (202) and receiver (203); a plurality of capacitors & resistors (205) for storing and resisting the electricity to power the said MOSFET (204) and driving the motor (105); and

Wherein the driving of the motor (105) powers the impeller fan (104) and cause the suction at the suction head (101) to suck the broken thread or yarn (400) inside the suction assembly (100) & then throws out in duct (110).

The suction head (101) is having suction at its tip; the motor (105) rotates the impeller fan (104) which creates suction at the tip of suction head (101), the broken thread or yam (400) is sucked from suction head (101) which is passed into the impeller assembly(103), the broken pieces of thread or yam (400) are passed into the impeller assembly (103) which are further passed into the duct (110), the device is connected to sensor box (208) consisting optical sensor assembly (s) (200) which turns on the motor (105) when thread or yam (400) break is detected.

Various aspects of the present invention 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.

BRIEF DISCRETION OF ACCOMPANYING DRAWINGS:

All aspects and advantages of the present invention will become apparent with the description of the preferred non limiting embodiment, when read together with the accompanying drawings, in which:

FIG 1 illustrates perspective & sectional view of position of the device of the present invention.

FIG 2 illustrates perspective and exploded view of device of the present invention. FIG 3 illustrates Optical sensor assembly of the present invention.

FIG 4 illustrates Dual suction head from one of the embodiment of the present invention.

Fig 5 illustrates the perspective view of ring frame machine.

DETAILED DESCRIPTION OF INVENTION: The present invention is related to device for power consumption reduction in ring frame/spinning. Present invention is device for power consumption reduction in ring frame/spinning for power consumption reduction in ring frame/spinning machine which saves power required to remove/suck the broken thread end fibrous fleece on ring frame/spinning. To explain specifically, the device for power consumption reduction in ring frame machine of present invention comprises: a) One or more suction assembly(s) (100) being placed within a duct (110) having: a suction head (101) connected to a threaded holder (102) which is fixed on an impeller assembly (103) for suction of broken thread or yarn (400) during manufacturing in the ring frame machine and; a threaded holder (102) for attachment & mounting of suction head (101) at one end and attachment of holding impeller assembly (103) at another end; an impeller assembly (103) consisting of an impeller fan (104) placed on impeller base (103’) and enclosed by an impeller cover (103”); and a motor (105) for powering the impeller fan (103.), b) One or more Optical sensor assembly(s) (200) being placed in contact with suction assembly (100) having: a PCB circuit (201) consisting of IR transmitter (202) and receiver (203) for transmission and reception of IR signals in the path of roving thread or yarn coming from drafting front pair of rollers delivery for co-relating it with the presence or absence of the thread or yam (400) and sending positive or negative feedback respectively to MOSFET (204); Presence of thread or yam refers to yam is not broken and absence of thread or yarn refers to yarn is broken. a MOSFET (204) for driving the motor (105) of suction assembly (100) upon receipt of negative feedback from the IR transmitter (201) and receiver (202); a plurality of capacitors & resistors (205) for storing and resisting the electricity to power the said MOSFET (204) and driving the motor (105); and wherein, the suction head (101) is having suction at its tip; the motor (105) rotates the impeller fan (104) which creates suction at the tip of suction head (101), the broken thread or yarn (400) is sucked from suction head (101) which is passed into impeller assembly (103), the broken pieces of thread or yarn (400) are passed into the impeller assembly (103) which are further passed into the duct (110), the device is connected to sensor box (208) consisting optical sensor assembly (s) (200) which turns on the motor (105) when thread or yam (400) break is detected.

Working of Invention:

The individual production centres have individual suction assembly (100) with individual impeller assembly (103) which initiates suction only when Optical sensor assembly (200) monitors absence of thread or yarn (400) and vice versa. Broken threads or yams (400) are intimated through individual optical sensor assembly (200) respectively to the respective suction assembly (100) & broken end fibrous fleece are sucked immediately through suction head (101). For individual threads or yams (400) during ring spinning, individual suction assembly (s) (100) & Optical sensor assembly (S) (200) are provided for monitoring. Plurality of Suction head (101) adjacent to each other are arranged beneath the front bottom roller, so as to collect the broken end fibrous fleece instantly after thread or yarn (400) break. Each single opening suction head (101) is connected to the corresponding individual impeller assembly (s) (103). Individual threads or yams (400) are monitored by Optical sensor assembly (s) (200). In case of any thread or yarn (400) breakage the corresponding individual suction assembly (100) activates for suction respectively. The suction is continued only till the thread or yarn (400) at its correct position is not detected by optical sensor assembly (200) .Once the thread is connected/joined or pieced respective Optical sensor assembly (200) monitors the thread or yarn (400) presence and stops the output to respective suction assembly (100). Thus only during of absence monitoring of thread or yam (400) by Optical sensor assembly (200) respective impeller assembly (103) creates suction.

The perspective sectional view of the device for power consumption reduction in ring frame machine constructed according to one of the preferred embodiment of invention is depicted in FIGURE 1, for explaining the components of the apparatus. Referring now to the FIGURES, more particularly to FIGURES 1 to 3, where similar reference characters denote corresponding features consistently throughout the FIGURES, preferred embodiments are shown.

FIG 1. & FIG 2., Illustrates perspective sectional view and exploded view of the device for power consumption reduction in ring frame machine constmcted according to one of the preferred embodiment of invention, which consists of a suction assembly (100) having impeller assembly (103) positioned in a duct (110) and the threaded holder (102) and suction head (101) positioned on outer side of duct (110) in relation so impeller assembly (103). The Optical sensor assembly

(200) is placed on the lappet (300).

FIG 3. Illustrates perspective view of the optical sensor assembly (200) according to one of the preferred embodiment of invention, which consists of an IR circuit

(201) having an IR transmitter (202) and receiver (203) for transmission and reception of IR signals in the path of roving thread or yam (400) coming from drafting front pair of rollers delivery for co-relating it with the presence or absence of the thread or yarn (400) and sending positive or negative feedback respectively to MOSFET (204), a plurality of capacitors & resistors (205) for storing and resisting the electricity to power the said MOSFET (204) and driving the motor (105).

In a preferred embodiment the device for power consumption reduction in ring frame machine of the present invention the construction materials are selected from plastics & metal combination thereof. In a preferred embodiment the Optical sensor assembly (200) of the present invention the construction materials are selected from plastics, composite plastics, metal, PCB and combination thereof.

In a preferred embodiment the multiple opening suction head (10F) is a dual suction head as shown in FIG 4. Dual suction head (10F) is arranged beneath the front bottom roller, so as to collect corresponding thread break. The other end of Dual suction head is connected to corresponding impeller assembly (103). Thread or yarn (400) is monitored by Optical sensor assembly (200) which senses the unavailability and gives output to impeller assembly (103) to start the suction. Plurality of Optical sensor assembly (s) (200), preferably 2 Optical sensor assembly (200) are connected to a single suction assembly (100) according to the present embodiment.

In a preferred embodiment more than two Optical sensor assembly (s) (200) can be connected to single suction assembly(S) (100).

In a preferred embodiment the Optical sensor assembly (200) consists of a micro controller (206) with variety of indicators (207) for indicating. The indicators are LEDs of different color to determine different signals like thread break, frequency of thread break and system working properly. Micro controller controls the signals received from the IR transmitter (202) and receiver (203) and further controls MOSFET to start/stop the motor (105) to generate suction at suction head (101). In a preferred embodiment the optical sensor assembly (200) is placed in a sensor box (208) having cover and holder and can be fitted on anti balloon control ring (301) and spinning ring.

EXAMPLE: For better understanding, calculations are as follows:

Following calculations are for various production centres per machine ranging from 1008 nos to 1824 nos & are based on usual shift of 8 hours, considering running yarn breakages level 5 breaks per 100 spindle per hour & single broken thread or yarn joining time of 15 seconds.

Considering below identical input parameters for conventional ring spinning machine suction system and current invention:

The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. 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.