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Measuring Devices in Carding | Part 05

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Md. Omar Faruk
Student of National Institute of Textile Engineering and Research
Md. Omar Faruk
Md. Omar Faruk

Latest posts by Md. Omar Faruk (see all)

Part 01 | Carding Introduction  | |   Part 02 | Carding Action

Part 03 |Card Clothing | Types of card clothing  | | Part 04 | Auto Leveling in Carding

Part 05 | Measuring Devices in Carding  | | Part 06 | Characteristics of Card Sliver

Measuring Devices in Carding 


Carding: Carding is a mechanical process that disentangles, cleans and intermix fibers s to produce a continuous web or sliver suitable for subsequent processing. In this process fibers are opened, parallelized & removes dust, impurities, short fibers to produce continuous strand of sliver. This is achieved by passing the fibers  between differentially moving surfaces covered with card clothing. The word is derived from the Latin “CARDUUS” meaning thistle or teasel, as dried vegetable teasels were first used to comb the raw wool.

Measuring Devices in Carding:

1 . Active Pneumatic System:

In a normal card, a funnel is provided before the calendar rollers (2) in order to collect the web into a sliver. In Zellweger equipment, this funnel is developed to form a measuring device based on a simple physical principle. When fiber material enters the funnel (3), it carries along quite an amount of air held between the fibers. Owing to the continuous convergence of the funnel, air is squeezed out as the material passes through.

This generates air pressure in excess of atmospheric pressure, which is a function of the sliver cross-section if the sliver speed is kept constant. If all fiber characteristics also remain constant, this pressure is proportional to the volume. A lateral bore (5) in the funnel, and corresponding leads, transmit the pressure into the chamber of a pneumatic-electrical pressure transducer, using electrical induction to convert the pressure into an electrical signal.

Comparison of the signal with a set value enables pulses to be generated to control the electronic units in the regulator equipment. The advantage of active pneumatic measurement lies in the simplicity of the system, which does not require additional and/or sensitive moving parts. The disadvantage is that measurement is affected by the fiber count and hence count variation can lead to errors.

Carding | Objectives of Carding | Purposes of Carding | Opening the tufts into individual fiber | Elimination of impurities | Elimination of Dust| Removal of short fiber | Blending of fibers |  Fibers orientation | Formation of sliver | Carding is The Heart of Spinning | Different types of carding machine | Roller and clearer card | Stationary flat card | Revolving flat card | Stationary flat carding machine | Revolving flat carding machine |  Mono Carding machine | Tandem carding machine | Working principle of carding machine | Parts of carding machine | Material passage diagram of carding machine | Feed roller- taker in zone | Taker in-cylinder zone | Cylinder-Flat zone | Cylinder-doffer zone | Actions in carding machine | Stripping action | Carding action | Doffing action | Difference among carding actions | Card clothing | Selection of card clothing | Types of card clothing | Flexible clothing | Advantages of flexible clothing | Disadvantages of flexible clothing | Metallic clothing | Advantages of metallic card clothing | Disadvantages of metallic card clothing | Semi-rigid clothing | Advantages of semi-rigid clothing | Geometry of card clothing | Auto leveling in Carding | Classification of Auto Leveling | Principle of short term auto leveling | Auto leveling in the in feed | The principle of medium-term auto leveling | The principle of long-term leveling | Measuring Devices in Carding | Active Pneumatic system | Mechanical measuring system | Carding angle | Striping in Carding | Methods of stripping in Carding | Roller stripping in Carding| Dustless stripper in Carding | Vacuum stripper in Carding | Air stripper in Carding | Continuous stripper in Carding | Static stripper in Carding | Grinding in Carding | Intervals between grinding | Grinding Depth in Carding |  Methods of grinding in Carding | Traverse wheel grinding | The dead roller or full width roller | Card clothing manufacturers | Card Wire specification | General faults in carding machine | Factors affecting carded clothing | Development in carding machine | Characteristics of card sliver |  Textile Study Center | textilestudycenter.com

Fig: Active Pneumatic system


2 . Mechanical Measuring System:

 This is the most common system for deriving a measured value. Usually, two material-forwarding rollers are used. One of these rollers must be movable (up and down) relative to the other. The relative movement, corresponding to the volume of the material passing through (a) gives the instantaneous value required for the regulation operation.

The rollers can be smooth or grooved, b and c. The latter arrangement prevents lateral escape of the fibers and thus gives more precise measurement. However, it must be so designed and must operate in such a manner that the fibers are not crushed at the roller edges.

The advantage of the mechanical principle lies in its insensitivity to variations in the characteristics of the raw material, with the possible exception of bulk.

Carding | Objectives of Carding | Purposes of Carding | Opening the tufts into individual fiber | Elimination of impurities | Elimination of Dust| Removal of short fiber | Blending of fibers |  Fibers orientation | Formation of sliver | Carding is The Heart of Spinning | Different types of carding machine | Roller and clearer card | Stationary flat card | Revolving flat card | Stationary flat carding machine | Revolving flat carding machine |  Mono Carding machine | Tandem carding machine | Working principle of carding machine | Parts of carding machine | Material passage diagram of carding machine | Feed roller- taker in zone | Taker in-cylinder zone | Cylinder-Flat zone | Cylinder-doffer zone | Actions in carding machine | Stripping action | Carding action | Doffing action | Difference among carding actions | Card clothing | Selection of card clothing | Types of card clothing | Flexible clothing | Advantages of flexible clothing | Disadvantages of flexible clothing | Metallic clothing | Advantages of metallic card clothing | Disadvantages of metallic card clothing | Semi-rigid clothing | Advantages of semi-rigid clothing | Geometry of card clothing | Auto leveling in Carding | Classification of Auto Leveling | Principle of short term auto leveling | Auto leveling in the in feed | The principle of medium-term auto leveling | The principle of long-term leveling | Measuring Devices in Carding | Active Pneumatic system | Mechanical measuring system | Carding angle | Striping in Carding | Methods of stripping in Carding | Roller stripping in Carding| Dustless stripper in Carding | Vacuum stripper in Carding | Air stripper in Carding | Continuous stripper in Carding | Static stripper in Carding | Grinding in Carding | Intervals between grinding | Grinding Depth in Carding |  Methods of grinding in Carding | Traverse wheel grinding | The dead roller or full width roller | Card clothing manufacturers | Card Wire specification | General faults in carding machine | Factors affecting carded clothing | Development in carding machine | Characteristics of card sliver |  Textile Study Center | textilestudycenter.com

Fig:  Mechanical measuring system

Carding angle: This is the most important angle of the tooth; the aggressiveness of the clothing, the hold of the fibers, is determined by this parameter. The angle specifies the inclination of the leading face of the tooth to a vertical. It is described as positive, negative or neutral. The angle is neutral if the leading edge of the tooth lies in vertical (0⁰). Clothing with negative angles is used only in taker-in, in processing of some synthetic fibers. Since the fibers are held less strongly by this form of tooth, they are transferred more easily to the cylinder and the clothing are less inclined to choke. Carding angles normally fall into following ranges:

Taker-in +5 to -10 (-15)

Cylinder +12 to +27

Doffer +20 to +40

Carding | Objectives of Carding | Purposes of Carding | Opening the tufts into individual fiber | Elimination of impurities | Elimination of Dust| Removal of short fiber | Blending of fibers |  Fibers orientation | Formation of sliver | Carding is The Heart of Spinning | Different types of carding machine | Roller and clearer card | Stationary flat card | Revolving flat card | Stationary flat carding machine | Revolving flat carding machine |  Mono Carding machine | Tandem carding machine | Working principle of carding machine | Parts of carding machine | Material passage diagram of carding machine | Feed roller- taker in zone | Taker in-cylinder zone | Cylinder-Flat zone | Cylinder-doffer zone | Actions in carding machine | Stripping action | Carding action | Doffing action | Difference among carding actions | Card clothing | Selection of card clothing | Types of card clothing | Flexible clothing | Advantages of flexible clothing | Disadvantages of flexible clothing | Metallic clothing | Advantages of metallic card clothing | Disadvantages of metallic card clothing | Semi-rigid clothing | Advantages of semi-rigid clothing | Geometry of card clothing | Auto leveling in Carding | Classification of Auto Leveling | Principle of short term auto leveling | Auto leveling in the in feed | The principle of medium-term auto leveling | The principle of long-term leveling | Measuring Devices in Carding | Active Pneumatic system | Mechanical measuring system | Carding angle | Striping in Carding | Methods of stripping in Carding | Roller stripping in Carding| Dustless stripper in Carding | Vacuum stripper in Carding | Air stripper in Carding | Continuous stripper in Carding | Static stripper in Carding | Grinding in Carding | Intervals between grinding | Grinding Depth in Carding |  Methods of grinding in Carding | Traverse wheel grinding | The dead roller or full width roller | Card clothing manufacturers | Card Wire specification | General faults in carding machine | Factors affecting carded clothing | Development in carding machine | Characteristics of card sliver |  Textile Study Center | textilestudycenter.com



Striping:

When the wire points of two closed surface are inclined to the opposite direction and both the surface rotate to the opposite direction then the action is called stripping direction. Stripping action occurs between taker-in and cylinder.

Methods of stripping:

  1. Roller stripping
  2. Dustless stripper
  3. Vacuum stripper
  4. Air stripper
  5. Continuous stripper
  6. Static stripper

1 . Roller stripping: Conventional method of stripping. A wooden roller of about 6” diameter and equal length to the card width, covered with a special stripping wire fillet is put against the cylinder by opening the front door. The stripping is done by passing the point of stripping roller to the cylinder wire by point to back action and with higher surface speed for the stripping roller.

2 . Dustless stripper: this method consists of plain roll, partially enclosed by sheet metal hood from which a large flexible tube leads to a special stripping truck. A small suction fan fitted on the truck exhausts into a fabric bag. It works exactly like roller stripping but brass normally is kept running during stripping. As a result, dust which would normally be thrown into the air is drawn away by the suction and collected in the dust bag.

3 . Air stripper: In this method truck is completely eliminated by one small stripping brush covered with special stripper clothing placed just above the junction of the doffer and cylinder. The roller is driven by main cylinder pulley through binder pulley.

4 . Vacuum stripper: No stripping roller is used. This system requires special air pump to maintain a high vacuum and large waste receiving drum where the waste is collected. Nozzle is used to collect waste from the surface of the cylinder or doffer etc.

5 . Continuous stripping: This is also nozzle and suction type stripping. It is automatic continuous stripping device. Its several advantages are given below:

  1. Reduction waste and saving in cotton.
  2. Reduction in labor cost required for stripping.
  3. More machine utilization and more production.
  4. More savings in power.
  5. More fillet life


Grinding: Grinding is the operation by which the good working condition of the wire points of all organs in the carding machine is maintained.

Intervals between grinding

The operating life of clothing is quoted in terms of the total throughput of material. For the cylinder it normally lies between 300,000 and 600,000 kg, but it can be higher in some circumstances.

The deterioration in quality from one grinding interval to the next arises from the fact that the teeth are ground down to successively lower heights, the lands at the teeth points become steadily larger, and softer metal layers are gradually exposed. The following grinding intervals are currently in use: 

 

Cylinder

Flats

First grinding after [kg]

80,000 – 150,000

80,000 – 150,000

Each additional grinding after [kg]

80,000 – 120,000

80,000 – 120,000

 

Grinding Depth:

Grinding is carried out with the cylinder rotating in its normal direction at normal speed, so that the grinding roller moves with (not against) the teeth of the clothing. The grinding depth is such that a plane surface with a sharp edge is produced at the point of the tooth (a). Satisfactory carding will not be achieved if too little material is ground away so that the front edge stays rounded (b), or if the grinding operation is too harsh (too much pressure on the grinding roller) so that a burr is formed at the tooth edge (c).

Carding | Objectives of Carding | Purposes of Carding | Opening the tufts into individual fiber | Elimination of impurities | Elimination of Dust| Removal of short fiber | Blending of fibers |  Fibers orientation | Formation of sliver | Carding is The Heart of Spinning | Different types of carding machine | Roller and clearer card | Stationary flat card | Revolving flat card | Stationary flat carding machine | Revolving flat carding machine |  Mono Carding machine | Tandem carding machine | Working principle of carding machine | Parts of carding machine | Material passage diagram of carding machine | Feed roller- taker in zone | Taker in-cylinder zone | Cylinder-Flat zone | Cylinder-doffer zone | Actions in carding machine | Stripping action | Carding action | Doffing action | Difference among carding actions | Card clothing | Selection of card clothing | Types of card clothing | Flexible clothing | Advantages of flexible clothing | Disadvantages of flexible clothing | Metallic clothing | Advantages of metallic card clothing | Disadvantages of metallic card clothing | Semi-rigid clothing | Advantages of semi-rigid clothing | Geometry of card clothing | Auto leveling in Carding | Classification of Auto Leveling | Principle of short term auto leveling | Auto leveling in the in feed | The principle of medium-term auto leveling | The principle of long-term leveling | Measuring Devices in Carding | Active Pneumatic system | Mechanical measuring system | Carding angle | Striping in Carding | Methods of stripping in Carding | Roller stripping in Carding| Dustless stripper in Carding | Vacuum stripper in Carding | Air stripper in Carding | Continuous stripper in Carding | Static stripper in Carding | Grinding in Carding | Intervals between grinding | Grinding Depth in Carding |  Methods of grinding in Carding | Traverse wheel grinding | The dead roller or full width roller | Card clothing manufacturers | Card Wire specification | General faults in carding machine | Factors affecting carded clothing | Development in carding machine | Characteristics of card sliver |  Textile Study Center | textilestudycenter.com



Methods of grinding:

  1. Traverse wheel grinding
  2. The dead roller or full width grinding roller.

Traverse wheel grinding:

In this method there is an emery roller of 3.5” width which moves from one side to another by traversing motion.Carding | Objectives of Carding | Purposes of Carding | Opening the tufts into individual fiber | Elimination of impurities | Elimination of Dust| Removal of short fiber | Blending of fibers |  Fibers orientation | Formation of sliver | Carding is The Heart of Spinning | Different types of carding machine | Roller and clearer card | Stationary flat card | Revolving flat card | Stationary flat carding machine | Revolving flat carding machine |  Mono Carding machine | Tandem carding machine | Working principle of carding machine | Parts of carding machine | Material passage diagram of carding machine | Feed roller- taker in zone | Taker in-cylinder zone | Cylinder-Flat zone | Cylinder-doffer zone | Actions in carding machine | Stripping action | Carding action | Doffing action | Difference among carding actions | Card clothing | Selection of card clothing | Types of card clothing | Flexible clothing | Advantages of flexible clothing | Disadvantages of flexible clothing | Metallic clothing | Advantages of metallic card clothing | Disadvantages of metallic card clothing | Semi-rigid clothing | Advantages of semi-rigid clothing | Geometry of card clothing | Auto leveling in Carding | Classification of Auto Leveling | Principle of short term auto leveling | Auto leveling in the in feed | The principle of medium-term auto leveling | The principle of long-term leveling | Measuring Devices in Carding | Active Pneumatic system | Mechanical measuring system | Carding angle | Striping in Carding | Methods of stripping in Carding | Roller stripping in Carding| Dustless stripper in Carding | Vacuum stripper in Carding | Air stripper in Carding | Continuous stripper in Carding | Static stripper in Carding | Grinding in Carding | Intervals between grinding | Grinding Depth in Carding |  Methods of grinding in Carding | Traverse wheel grinding | The dead roller or full width roller | Card clothing manufacturers | Card Wire specification | General faults in carding machine | Factors affecting carded clothing | Development in carding machine | Characteristics of card sliver |  Textile Study Center | textilestudycenter.com

 

Advantages:

  1. Better grinding action.
  2. No risk of hooking or fusing of wires.

The dead roller or full width roller:

Here rotate covering the full width of the card. Roller is covered with emery fillet.

 Carding | Objectives of Carding | Purposes of Carding | Opening the tufts into individual fiber | Elimination of impurities | Elimination of Dust| Removal of short fiber | Blending of fibers |  Fibers orientation | Formation of sliver | Carding is The Heart of Spinning | Different types of carding machine | Roller and clearer card | Stationary flat card | Revolving flat card | Stationary flat carding machine | Revolving flat carding machine |  Mono Carding machine | Tandem carding machine | Working principle of carding machine | Parts of carding machine | Material passage diagram of carding machine | Feed roller- taker in zone | Taker in-cylinder zone | Cylinder-Flat zone | Cylinder-doffer zone | Actions in carding machine | Stripping action | Carding action | Doffing action | Difference among carding actions | Card clothing | Selection of card clothing | Types of card clothing | Flexible clothing | Advantages of flexible clothing | Disadvantages of flexible clothing | Metallic clothing | Advantages of metallic card clothing | Disadvantages of metallic card clothing | Semi-rigid clothing | Advantages of semi-rigid clothing | Geometry of card clothing | Auto leveling in Carding | Classification of Auto Leveling | Principle of short term auto leveling | Auto leveling in the in feed | The principle of medium-term auto leveling | The principle of long-term leveling | Measuring Devices in Carding | Active Pneumatic system | Mechanical measuring system | Carding angle | Striping in Carding | Methods of stripping in Carding | Roller stripping in Carding| Dustless stripper in Carding | Vacuum stripper in Carding | Air stripper in Carding | Continuous stripper in Carding | Static stripper in Carding | Grinding in Carding | Intervals between grinding | Grinding Depth in Carding |  Methods of grinding in Carding | Traverse wheel grinding | The dead roller or full width roller | Card clothing manufacturers | Card Wire specification | General faults in carding machine | Factors affecting carded clothing | Development in carding machine | Characteristics of card sliver |  Textile Study Center | textilestudycenter.com

Advantage:

  1. Long grinding roller is used in case of high speed grinding.
  2. It is used to produce low and medium count yarn

Part 01 | Carding Introduction  | |   Part 02 | Carding Action

Part 03 |Card Clothing | Types of card clothing  | | Part 04 | Auto Leveling in Carding

Part 05 | Measuring Devices in Carding  | | Part 06 | Characteristics of Card Sliver


(54)

Md. Omar Faruk
Student of National Institute of Textile Engineering and Research
Md. Omar Faruk
Md. Omar Faruk

Latest posts by Md. Omar Faruk (see all)

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