The starting point in the preparation of the blend in the production of nonwovens, the use that the desired textile surface should have features and price. Accordingly, the fiber type or types to be added to the blend are determined. In order for the blending degree to be perfect, the selection of fiber types with the same fiber length should be made at the earliest stage of production. Cotton fiber and textile fibers used with cotton are stocked in the form of pressed bales at the nonwoven factory according to the capacity of the blowroom. Working with cotton on a daily basis is difficult. There should normally be a stock available to meet the quarterly requirement. Cottons are stored in the warehouse of the factory in bales. Bales should not be placed on concrete floors, but should be placed on grids and their height should not exceed 10 m when stacked. In addition, there should be enough spaces between the bales for a person to walk around. Thus, aeration and transportation of stored bales is facilitated. The average weight of the bales is 220-230 kg for imported cotton bales and 210 kg for domestic cotton bales. The quality of the cotton, the way it was ginned, the place where it was grown and the control seal must be on the bale.
The temperature in the blowroom should be above 23 degrees Celsius and the relative humidity should be 45-60%. High humidity, insufficient opening degree; low humidity causes the fibers to be damaged. In an enterprise with standard air conditioning conditions, the bales are taken into the blowroom chamber at least 24 hours in advance, and the cotton bales are adapted (adapted) to the climate conditions by opening the circles. This process is called conditioning or conditioning of cotton fiber. The amount of fiber that has been rested and adapted to the air conditioning conditions in the blowroom is called raw stock.
Bale Label and Reading
There are various markings on the bale packaging. These signs give information about cotton in bales. On the pressed cotton bales in Turkey and other countries, there is a label with an official brand, signs and control seal showing the characteristics of the cotton inside.
Two examples showing the official marks and signs that should be on the outside of the bale are shown below.
1. Sawgin bale 2. Rollergin bale
TURKEY TURKEY
ST.(1) ST. (HB2)
CONTROL SEAL CONTROL SEAL
İZMİR 15-025 K.MARAŞ 2-010
SAWGIN 2007 ROLLERGIN 2007
For this purpose, the operator should evaluate the baled cotton presented to him according to the following criteria:
1-The quality of the bale
a- The color of the cotton and the type of color, brightness, density, yellow spots arising from disease, frost and gathering in damp weather
b- Foreign substances and their amounts
c-Ginning quality of cotton
2-Moisture of cotton
3-Fiber length
4-Other fiber properties
Numerical values of properties such as fiber length distribution, fiber fineness (micronaire size), breaking strength (pressley value), maturity, brightness, curl, amount of foreign matter; seed, soil content, climatic conditions, collection, storage and ginning factors vary due to the difference in conditions.
Reading the Blend Recipe
The blending efficiency is calculated by determining how much of the fiber amount entering the plant is involved in the production of cheesecloth for the nonwoven surface. Foreign materials and short fibers in the cotton taken into operation are separated as waste at various stages. The threshing efficiency is found by proportioning the amount of fiber entering the blend and the amount of cheesecloth obtained.
Placing the Bales in the Mixer
Different fiber types or a single type of fiber can be used in the production of cheesecloth that is desired to be produced in nonwoven surface enterprises. In both cases, the blending process must be applied. Because there are varieties with very different fiber properties of the same fiber type. In order to obtain a homogeneous fiber group, it is absolutely necessary to apply the blending process to the fiber or fiber types to be used in the production of cheesecloth. The bales are brought from the cotton warehouse to the blowroom. According to the previously prepared threshing recipe, the bales are placed around the threshing machine. Here, the circles around the bales are cut and the cross-stitch is removed. In order for these cottons in the form of bales to work comfortably under operating conditions, they should be kept for 20-24 hours in air conditioning conditions at a temperature of 0–50 °C and 24% relative humidity. The purpose of this is to open and swell the cotton masses that are compressed due to the press during baling and to have the desired climate conditions.
Blending Techniques
There are two types of blending techniques in the blending of cotton fiber and textile fibers used with cotton in the tufting surface formation process.
A-Stacking mix
If cotton fibers are to be mixed with other fibers (artificial, synthetic, etc.) in the blend, this blend can be preferred. Different types and quantities of raw materials in the blend recipe are stacked on top of each other to form a regular rectangular prism. Then, the pieces taken by cutting vertically are fed to the bale opener machine. Obtaining a proper blend in this method depends on the careful work of the worker.
Blend of cottons of different quality according to the determined recipe;
a-In the classical system: The feeding mat of the threshing bale opener is provided by the worker by feeding the bales lined up around it.
b-In the modern system: It is provided by feeding with the robot arm over the bales lined up under the robot arm of the Unifloc (automatic bale opener) machine.
Classic Bale Opening Machine
It is the first machine of the blow room. Bale opener is a hopper and mat opening machine in which the pellets taken from the bale by the worker are fed.
Duties
A-Blending cotton fibers or blends,
Opening (mixing) the B-fiber tufts,
It is to clean C-Fibers from foreign materials (bark, garbage, metal particles, dust, etc.).
Technological Diagram
a- Feeding mat b- Conveying mat c- Nailed (needle) mat d- Back scraper roller e- Receiving roller h- Grid L- Print rollers ı- Material output j- Dust and foreign matter k- Photocell m- cleaning roller
Working Principle
Regardless of the type of bale opener machines, the working principle is the same. The only change is the shapes of the parts, their relative positions and some small mechanical parts added to make the machine work better. For the bale openers to be good threshing, the number of bales should be as large as possible, the carrier mat should be of sufficient length and there should be enough space next to the machine to put the bales.
Generally, cotton taken regularly from 8-12 bales and fibers used together with cotton are fed into the bale opening machine. Since the cotton pieces processed in 4 bale openers installed side by side are poured on the same conveyor belt, the cotton in 32-48 bales is mixed at the end of the belt. Cotton pieces taken from the bales are placed on the feeding mat. The chamber of the bale opener is kept ¾ filled with cotton. When the chamber is ¾ full, feeding is automatically stopped by the photocell in photocell machines and by the control plate in machines with control plate, and jamming in the chamber is prevented. That's why the feeding mat works intermittently. The cotton pieces are conveyed from here to the shipping mat. The fiber in the shipping mat comes into the needle mat. In the needle mat, the distance between the needles is 3-5 cm, and the mat is inclined to make an angle of 70-800. The needle mat quickly picks up the cotton balls; In the meantime, the cotton fiber is opened and loosened a little, the excess of the fiber layer on the mat is poured back into the chamber in small pieces by the scraper rollers, and the opening and blending degree of the fiber is increased. The degree of opening of the fiber and the production capacity of the machine can be increased or decreased by adjusting the distance between the needle mat and the back stripper roller.
The cotton layer remaining on the needle mat is taken over the needle mat by the receiving rollers and fed to the feeding line. The opening roller, which is covered with small nails, opens the cotton and allows it to be cleaned by pouring the loosened foreign materials inside by hitting the grids underneath. The dusts formed during the blending and opening processes are drawn by the air flow created with the help of a fan and removed from the environment (collecting into the filters).
Machine Maintenance
In order to be able to produce quality products with the machinery and equipment used in the enterprise, and to use the machinery and equipment efficiently, smoothly, safely and for a long time, machine maintenance techniques should be well known and applied in a timely manner. It is seen that the main causes of faults on the web are due to uneven feeding, careless working, unmaintained machines. For these reasons, both the machine maintenance revisions and adjustments and the worker's tendency to work more carefully are among the factors to be sought.
A- Work accidents will be prevented,
B- The life of the machine will increase,
C- The efficiency of the machine will increase,
D-Operational safety will increase,
E-Energy will be saved,
F- Waste of raw materials will be prevented,
G-Spare parts will be saved.
Machine maintenance is generally done in three ways:
1-Cleaning
2-Daily maintenance
3-Planned maintenance (renewal)
It is essential to provide a scheduled and periodic maintenance to the threshing room machines. The plan should be made in such a way that the threshing machines should be revised every 600 working hours at the most. The machine must be kept under control during operation.
1-The bearings and bearings of the delivery rollers, which help the feeding and conveying mats in the transmission of motion, must be lubricated with solid oils (grease) every 168 working hours.
3-Needle wicker needles should be checked once a month, bent ones should be corrected.
4-Broken needles should be replaced with new ones.
5-Back scraper, cleaning roller, grate opening roller, receiver roller, bearings should be lubricated every 168 working hours.
6-Oil overflowing during lubrication should be cleaned with oakum
Machine's Settings
Belt tension adjustment: It should be ensured that the belts of the machine are at normal tension (Picture 2.3). Over-tensioned belts cause the bearing, shaft and pulleys to wear out in a short time. In case of working with a loose belt, the speed of the machine, and therefore its production, decreases due to the excessive slippage.
Needle wire mesh tension adjustment: The spring pulley system works like a conical pulley system, changing the speed with belt tensioning and movement, so the speed of the needle mesh can be adjusted. The point to note is that the needle mesh speed should only be adjusted during operation. It is not possible to adjust while stationary. It causes the belt to come off or the spring pulley to break. This adjustment is made with the horizontal steering wheel tensioning the belt. The setting indicator ranges from 1 to 6.
Needle mat adjustment with scraper roller: There are 8 rows of needles on the back stripper roller, in a diagonal arrangement. The needles are screwed to the iron bar with gaskets. The distance between the back stripper roller and the needle mesh can be adjusted between 10 and 40 mm with a steering arm. If the distance between the back stripper roller and the needle mesh is less, the fiber opens better. Neps decreases, along with production decreases.
Cleaning roller adjustment with back scraper roller: Back scraper roller is fixed, cannot be adjusted. However, the cleaning roller should be such that it touches the hooked end of the needles.
Needle mat adjustment with the receiving roller: It can be done between the limits of 10-25 mm by loosening the beds.
Cleaning of the Machine Before and After the Process
The machine worker cleans the dust, fiber fly, on or around the working machine, between work and when the machine is stopped. Apartment cleaning workers also do their daily and weekly cleaning.
The magnetic cylinder, which catches the metal parts that are likely to be found in the cotton at the exit of the machines, should be cleaned by the worker. Surfaces that need to be wiped clean, such as oil stains, are cleaned with diesel or kerosene. Never use a mixture of water and detergent. This causes rust and wear (corrosion).
Fiber Feeding to the Machine
According to the threshing recipe, bales are placed around the feeding mat of the classical bale opener machine. The cottons taken from the bales by the workers are opened in small tufts and left on the feeding mat. It should never be left in the form of tufts. Because these pinches cause the machine to work longer. This injures and breaks the fibers.
AUTOMATIC BALE OPENING MACHINE
It is the first machine to feed baled cotton in modern blowrooms. These machines are replacing bale opening machines in today's nonwoven mills. Bale plucking machine is a machine that plucks the fibers from a certain number of bales in small tufts and provides a uniform (homogeneous) mixture and cleans them (Automatic bale opening machine is called a bale machine in the blowroom.
Duties
1-Opening the fiber
2-Mixing the fiber
3- To clean the fiber from foreign materials (bark, garbage, metal particles, dust, etc.)
Working units of the bale opener shown in the figure
1-Control Cabinet
2-Bale sorting area
3-Receiving unit
4-Rotating tower with drive unit
5-Material transfer channel
Working Principle
The cotton bales, which have different fiber properties and come from different regions, are arranged on the floor of the flat on one or both sides of the bale opener depending on the floor width. The Unifloc receiving unit works with a capacity of approximately 180 kg per hour by moving over the bales parallel to the bales (6-13 m/min.). There are two roller groups on the receiving unit, two corrective rollers and one receiver. Small fiber bundles are broken off with a receiving (opening) roller working together with a grid. The receiving unit has the feature of moving up and down, and the pluckers move downwards according to the bale density, pulling the fiber tufts by pulling the fiber tufts while passing over the bale routinely.
The plucked fiber tufts are then conveyed to the next machine by moving through the suction channel under the machine. There is a helical gear on the receiving roller. It is surrounded by a grill on one side. As a result of the harmonious work of these working elements, it is possible to open the cotton in small bundles at high yields.
In addition, the task of the grid is to prevent the bale from tipping over during operation with the help of two support shafts. Another feature is that it is possible to open and mix bales of different formats in a single operation, thanks to the automatic programmable bale opening mechanism. While the first round is being made, the stacked bales are divided into a maximum of four different height formats, and the height of each group is automatically determined and memorized. Then the bales continue to be processed. After processing the bales on one side of the Unifloc, the receiver head makes 1800 turns and this time starts to process the stock on the opposite side. Processing is only one-way to ensure a homogeneous mixture. If the work is done in both directions, the efficiency can be increased by 25%. The finer the fiber is plucked, the higher the probability of foreign materials coming to the surface, so the fiber can be cleaned more effectively in subsequent machines.Factors affecting the degree of plucking can be listed as:
1-Size of fiber bales,
2- Density degree of fibers,
3-The adhesion between the fibers (friction),
4-The confusion state of the fibers,
5-Working speed of the opening machine,
6-Bale opener cylinder type,
7-Climate conditions in the enterprise.
Machine Maintenance
In order to be able to produce quality products with the machinery and equipment used in the enterprise, and to use the machinery and equipment efficiently, smoothly, safely and for a long time, machine maintenance techniques should be well known and applied in a timely manner. It is seen that the main causes of faults on the web are due to uneven feeding, careless working, unmaintained machines. For these reasons, both the machine maintenance revisions and adjustments and the worker's tendency to work more carefully are among the factors to be sought.
Machine maintenance is generally done in three ways:
1-Cleaning
2-Daily maintenance
3-Planned maintenance (renewal)
Cleaning and lubrication of the drive gears and chains of the plucker and corrective rollers is done every 500 working hours. Cleaning and lubrication of the drive gear and chains of the extractor unit is done every 1500 working hours. Again, every 1500 working hours, the engine lining is cleaned. The engine transmission oil change, which drives the Unifloc main engine, is also done every 1500 hours.
1- Work accidents will be prevented,
2- The life of the machine will increase,
3- The efficiency of the machine will increase,
4-Operational safety will increase,
5-Energy will be saved,
6- Waste of raw materials will be prevented,
7-Spare parts will be saved.
Machine's Settings
The Unifloc take-up unit is 6-13 m/min. parallel to the bales. It works with a capacity of approximately 1500 kg per hour by navigating rapidly. The setting here directly affects the production.
Thanks to the automatic programmable bale opening mechanism, bales of different formats can be opened and mixed in equal proportions in a single operation.
Cleaning of the Machine Before and After the Process
The machine worker cleans the dust, fiber fly, on or around the working machine, between work and when the machine is stopped. Apartment cleaners also do daily and weekly cleaning with brushes, cleaning guns and vacuum cleaners.
Surfaces that need to be wiped clean, such as oil stains, are cleaned with diesel or kerosene. Never use a mixture of water and detergent. This causes rusting and wear (corrosion).
Waste Opener Machine
During the stage that the fiber passes until it becomes cheesecloth, some rashes occur. Some of these spills may be added back into the mix. Those that can rejoin the blend are called good spills or waste. The machine that brings the waste back to the threshing floor is called the waste opener machine.
Good waste and waste are obtained from the places described below.
Faulty laps: They are the lap runners and defective laps obtained at the exit of the chamber machine and feeding to the carding machine.
Cheesecloth wastes: It is the inside and outside of the card waste during the production of the card. These are the samples taken for cheesecloth controls.
Duties
1-Blending good waste
2-To open the fiber tufts.
3- To clean the fibers from foreign materials (cotton cocoon shell pieces, garbage, metal particles, dust, etc.)
Technological Diagram
Working elements of waste opener machine:
a. feeding mat
b. shipping mat
c. Needle wire mesh
D. back scraper
to. Receiver cylinder
f. Grill
g. material output
h. wastes
I. checker plate
j. Dust and foreign matter
Working Principle
Regardless of the type of waste opener machines, the working principle is the same. The only changes are the shapes of the parts, their relative positions and some small mechanical parts added for better operation of the machine.
All enterprises have one waste clearing machine in their threshing floor. The waste on the feeding mat is sent onto the shipping mat. The hopper of the waste opener is kept ¾ filled with fiber. When the chamber is ¾ full, feeding is automatically stopped by the photocell in photocell machines and by the control plate in machines with control plate, and jamming in the chamber is prevented. Therefore, the feeding mat works intermittently. The fiber is conveyed from here to the shipping mat. The fiber in the shipping mat comes to the needle mat. In the needle mat, the distance between the needles is 3-5 cm. The mat is inclined to form an angle of 70-800. The needle mat quickly takes the waste on it, while the waste is opened and loosened a little. The excess fiber layer on the mat is poured back into the chamber in small pieces by the scraper rollers. The opening and blending degree of the fiber is increased. The degree of opening of the fiber and the production capacity of the machine can be increased or decreased by adjusting the distance between the needle mat and the back stripper roller. The fiber layer remaining on the needle mat is taken off the needle mat by the receiving rollers; fed into the supply line. The opening roller, which is covered with small nails, opens the fiber and ensures that the loosened foreign materials are poured out and cleaned by hitting the grids underneath.
Machine Maintenance
In order to be able to produce quality products with the machinery and equipment used in the enterprise, and to use the machinery and equipment efficiently, smoothly, safely and for a long time, machine maintenance techniques should be well known and applied in a timely manner. It is seen that the faults on the web are caused by uneven feeding, careless working, unmaintained machines. For this reason, it is necessary to pay attention to both the machine maintenance revision and adjustments and the more careful work of the worker. It is essential to provide a scheduled and periodic maintenance to the threshing room machines. The plan should be made so that threshing machines should be overhauled at a maximum of 2160 working hours. The machine must be kept under control during operation.
1-The bearings and bearings of the delivery rollers, which help the feeding and conveying mats in the transmission of motion, must be lubricated with solid oils (grease) every 720 working hours.
2-Needle mat and back scraper needles should be checked once a month and bent ones should be corrected.
3-Broken needles should be replaced with new ones.
4-Back scraper, cleaning roller, grating opening roller, receiving roller bearings should be lubricated every 720 working hours.
5-Oils that come out during lubrication should be cleaned with oakum.
Machine's Settings
The set points of the machine are as follows.
1- Belt tension adjustment: It should be ensured that the belts of the machine are at normal tension. Over-tensioned belts cause bearings, shafts and pulleys to wear out in a short time. In case of working with a loose belt, excessive slippage reduces the speed of the machine and thus the production.
2-Needle mat tension adjustment: The spring pulley system works like a conical pulley system, and the speed is changed by belt tensioning and movement, and thus the speed of the needle mat can be adjusted.
3-It should be noted that the needle mesh speed should only be adjusted at the time of operation. It is not possible to adjust while stationary. It will cause the belt to come off or the spring pulley to fail. This adjustment is made with the horizontal steering wheel tensioning the belt. The adjustment indicator is from 1 to 30 mm.
Needle mat adjustment with scraper roller: There are 8 rows of needles on the back stripper roller, in a diagonal arrangement. The needles are screwed to the iron bar with gaskets.
The distance between the scraper roller and the needle mat can be adjusted from 10 to 40 mm with a steering arm .
If the distance between the back stripper roller and the needle mat is less, the fiber opens better. Neps decreases, but production also decreases.
Cleaning roller adjustment with scraper roller: Back stripper roller is in a fixed state. It cannot be adjusted, but the cleaning roller should be such that the leather cleaners lightly touch the hooked end of the needles.
Needle mat adjustment with receiving roller: The setting here can be adjusted by 10-25 mm by loosening the bearings.
Cleaning of the Machine Before and After the Process
The machine worker cleans the dust, fiber fly, on or around the working machine, between work and when the machine is stopped. Apartment cleaning workers also do their daily and weekly cleaning.
STEP OPENING
Step Bale Opening Machine
They are machines that perform partially opened fiber opening and cleaning operations in classical bale openers.
Duties
Opening the fiber in the gap
Blending (blending) the fiber
To effectively clean foreign materials such as short fiber, dust, seeds, trash in the fiber.
Technological Scheme
Working elements of the step opener shown in the figure:
a. Beater (opening) rollers (6 pcs)
b. Braking plates (4 pcs)
c. Grids
D. Container where foreign materials are poured
Working Principle
Fibers that are partially opened and cleaned in conventional bale openers; enters from the entrance of the machine. Working width is 1000 mm. Working system consists of three main parts:
Beater (opener) rollers
The beater (opening) rollers were 6 in total). There are 4 rows of braking plates on both beater rollers. Their task is to ensure that the fibers are swept away by the centrifugal force generated by the rotation of the beater rollers. The braking plates between the rollers allow the fibers to stay longer around the beater roller by striking them, allowing them to be opened and cleaned better.
Grids
There are thick type grids under each beater roller. Total 102 pieces. These grilles have an adjustment system that will change their angles from the outside with 6 arms. It is opened or closed from the outside according to the cleanliness level of the cotton.
spill hopper
It is the part where debris accumulates under the grids. In this machine, the cleaning rate of foreign materials in the fiber is up to 60-65%.The fiber, which passes through all these processes, passes from the exit of the machine to the next machine with the help of delivery pipes and air flow.
Machine Maintenance
In order to be able to produce quality products with the machinery and equipment used in the enterprise and to work with them efficiently, smoothly, safely and for a long time, machine maintenance techniques must be well known and applied in a timely manner. It is seen that the faults on the web are caused by uneven feeding, careless working, unmaintained machines. Therefore, both the machine maintenance revisions and adjustments and the worker's tendency to work more carefully are among the factors to be sought.
1- Work accidents will be prevented,
2- The life of the machine will increase,
3- The efficiency of the machine will increase,
4-Operational safety will increase,
5-Energy will be saved,
6- Waste of raw materials will be prevented,
7-Spare parts will be saved.
Machine maintenance is generally done in three ways:
1-Cleaning
2-Daily maintenance
3-Planned maintenance (renewal)
It is essential to provide a scheduled and periodic maintenance on the threshing room machines. The plan should be made so that the threshing machines should be overhauled every 600 working hours at the most. Beater cylinder arms should be checked once a month, bent ones should be corrected. Oils that come out during lubrication should be cleaned with oakum.
Machine's Settings
Belt tension adjustment
It should be ensured that the belts of the machine are in normal tension.
Over-tensioned belts cause bearings, shafts and pulleys to wear out in a short time. In case of working with a loose belt, the production of the machine decreases due to the speed of the machine due to excessive slip.
Braking plate adjustment with beater roller
These distance settings should be 30 -40 – 50 – 60 mm from the machine inlet to the exit. If the cleaning and opening degree of the fiber is not sufficient, it can be closed a little.
Grid settings
These distance settings should be 3,5 – 3 - 2,5 -2- 1,5 -1 mm from the machine input to the output.
Cleaning of the Machine Before and After the Process
The machine worker cleans the dust, fiber fly, on or around the working machine, between work and when the machine is stopped. Apartment cleaning workers also do their daily and weekly cleaning.
The debris hopper should be cleaned at least twice per shift, or three times if the fiber is very dirty. Internal and external cleaning of the machine should be done at the beginning of each shift. If these necessary cleanings are not done, fiber jams may occur and cause damage to the machine. Surfaces that need to be wiped clean, such as oil stains, are cleaned with diesel oil or kerosene. Never use a mixture of water and detergent. This causes rusting and wear (corrosion).
SINGLE (MONO) OR MULTI-CYLINDER CLEANER
Mono Roller Opener (Cleaner)
Mono roller opener (cleaner) is an effective cleaning and dust separating machine used right after the automatic bale opener (Blendomat, Unifloc). It has two models. The difference between the two models is their production capacity.
1-Uniclean B 11 Max. production is 1200 kg/h.
2-Uniclean B 12 Max. production is 1400 kg/h.
Duties
1-Opening the fiber in the best way
2-Mixing the fiber in the best way
3- To effectively clean the fiber from foreign materials (grass particles, garbage, metal particles, dust, etc.).
Technological Diagram
Technological scheme of single cylinder cleaner (Uniclean B 11) machine
Working Principle
It is in the form of the cylinder covered with nails (pins) opening and pulling the cotton layer thinning and loosening the fiber layer (while advancing with the resulting air flow) and separating the heavy foreign materials from the fiber by pouring them into the waste chamber through the grids.
During production, the raw material is passed through the integrated dust separation filter, where dust, fiber particles and seed coats are mechanically cleaned. This cleaning process takes place in a controlled and effective manner with airflow.
The difference between the wastes of the classical-modern blowroom machines can be seen below. Usable fibers from the machines used in the classical system are also included in the waste.
Machine Maintenance
In order to be able to produce quality products with the machinery and equipment used in the enterprise, and to use the machinery and equipment efficiently, smoothly, safely and for a long time, machine maintenance techniques should be well known and applied in a timely manner. It is seen that the faults on the web are caused by uneven feeding, careless working, unmaintained machines. For this reason, both the machine maintenance, revision and adjustments and the worker's tendency to work more carefully are among the factors to be sought.
Machine maintenance is generally done in three ways:
1-Cleaning
2-Daily maintenance
3-Planned maintenance (renewal)
It is essential to provide a scheduled and periodic maintenance for the threshing room machines. The plan should be made in such a way that the threshing machines should be overhauled every 600 working hours at the most. Cleaning roller nails (pins) should be checked once a month and bent ones should be corrected. Oils that overflow during lubrication should be cleaned with oakum.
1- Work accidents will be prevented,
2- The life of the machine will increase,
3- The efficiency of the machine will increase,
4-Operational safety will increase,
5-Energy will be saved,
6- Waste of raw materials will be prevented,
7-Spare parts will be saved.
Machine's Settings
Cleaning intensity and waste amount are two independent adjustment parameters and they constitute the limit of the selective cleaning process of Uniclean B 12. Each of the 110 working points of the Varioset corresponds to a setting for the material velocity and the grid angle. Two values are entered into the Varioset.
1-A value between 0,0-1,0 as the cleaning intensity,
2-A value between 1 and 10 is entered as the relative waste amount.
These values are loaded directly from the machine or with the control system. The settings are repeatable. This ensures a high level of operating suitability even with frequent blend changes. If unifloc is working with different blends, the material-specific operating point is automatically selected in Uniclean.
Cleaning of the Machine Before and After the Process
The machine worker cleans the dust, fiber fly, on or around the working machine, between work and when the machine is stopped. Apartment cleaning workers also do daily and weekly cleaning with brushes, cleaning guns and vacuum cleaners. Surfaces that need to be wiped clean, such as oil stains, are cleaned with diesel oil or kerosene. Never use a mixture of water and detergent. This causes rust and wear (corrosion).
Multi-Roll Opener ( Cleaner / Axi-flo )
It is a classic blowroom machine (Picture 3.10). It works after the bale opener. This machine is called horizontal opener in enterprises.
Duties
1- Mixing the fiber from the bale opener effectively
2-Opening the fiber
3- To make an effective cleaning.
Working Principle
This machine consists of two cleaning rollers and screens placed parallel to each other. The roller surface is covered with needles. The needles are arranged helically on the cylinder surface. The fiber enters the machine from the fiber inlet. Cleaning rollers open and clean the fiber. In the meantime, foreign materials in the fiber fall down from the screens into the waste chamber due to the effect of centrifugal force and their specific gravity. The cotton fibers that are opened and cleaned pass to the other machine from the fiber exit part.
Machine Maintenance
Cleaning and lubricating the drive gears and chains of the cleaning roller is done every 1500 working hours. Cleaning roller nails should be checked once a month and bent ones should be corrected. Machine maintenance is generally done in three ways:
1-Cleaning
2-Daily maintenance
3-Planned maintenance (renewal)
Machine Settings Adjusting the degree of cleanliness of the fiber
The degree of cleanliness of the fiber can be adjusted by adjusting the distance between the grids and the cleaning rollers. The cleaning degree of the fiber can be adjusted by changing the cleaning roller speeds. The speed of the cleaning roller is 685 rpm. should be. Grid settings can be adjusted according to the properties of the nonwoven web to be obtained and depending on the desired degree of cleanliness.
Cleaning of the Machine Before and After the Process
The machine worker cleans the dust, fiber fly, on or around the working machine, between work and when the machine is stopped. Apartment cleaners also do daily and weekly cleaning with brushes, cleaning guns and vacuum cleaners. Surfaces that need to be wiped clean, such as oil stains, are cleaned with diesel or kerosene. Never use a mixture of water and detergent. This causes rust and wear (corrosion).
BLENDING MACHINE
Unimix Threshing Machine
Unimix is one of the threshing chamber machines. It is the machine where the fibers are mixed as well as possible and the homogeneity of the mixture is ensured.
Duties
1-To blend cotton and fibers used with cotton homogeneously.
2-Opening the fiber tufts
3- To clean the fibers from foreign materials (cotton cocoon and shell pieces, garbage, particles, dust, etc.)
Working Principle
The fiber comes to the machine with a turbulent air flow. There are closing flaps at the top of the mixing chambers. Closing flaps allow the fiber to be poured into the mixing chambers. Filling of the fiber into the mixing chambers at the specified level is adjusted by photocell. When the fibers are filled to the mixing chamber at the specified level, the flaps are closed and the entry of the fibers is prevented. When the fiber is not taken at the determined level, the flap opens and provides fiber entry. In this way, the fiber is fed in 6 mixing chambers.
The material is compressed pneumatically and dust is removed. After turning 90 degrees, layers are formed by putting the fiber layers on top of each other. The feeding band delivers the cotton to the spiked upright mat. The material coming to the vertical needle mat moves up. Excess parts are transferred back with the scraper roller. These processes allow the fiber to be mixed. It is poured on the fiber opener, which is opened between the back scraper and the mat. Foreign materials in the fiber stuck between the blades of the opener pass through the grate to be poured and accumulate in the waste box. The material coming out from here is fed according to the request of the next machine ERM or uniflex. The machine does not emit dust and noise.
Machine Maintenance
To be able to produce quality products with the machinery and equipment used in the enterprise; In order to ensure that machinery and equipment can be used efficiently, smoothly, safely and for a long time, machine maintenance techniques must be well known and applied in a timely manner. Errors on cheesecloth; It is seen that it is caused by uneven feeding, careless work, unmaintained machines. For this reason, machine maintenance, revision and settings should not be neglected and the worker should work more carefully. It is imperative that the threshing room machines are maintained in a scheduled and periodical manner. The maintenance program should be made in such a way that the threshing machines undergo a monthly overhaul. Conveying roller, chain, bearing and bearings that help the feeding band and conveying mats in the transmission of motion should be lubricated with liquid and solid oils (grease) once a month.
Needle mat and back scraper needles should be checked once a week, bent ones should be corrected.
1-Broken and bent needles should be replaced with new ones.
2-Belts and chains should be checked once a week and stretched if necessary.
3-Functions of photocells should be checked once a week.
4- Feeding band, back scraper and bearings should be lubricated once a month.
5-Oils that come out during lubrication should be cleaned with oakum.
Machine Settings
1- Belt tension adjustment: It should be ensured that the belts of the machine are at normal tension. Over-tensioned belts cause bearings, shafts and pulleys to wear out in a short time. In case of working with a loose belt, slippage is high and production decreases due to the speed of the machine.
2-Needle mesh tension adjustment: Spring pulley system works like a conical pulley system. With the belt stretching and movement, the speed is changed and therefore the speed of the needle mat can be adjusted. It should be noted that the needle mesh speed is only adjusted during operation.
3- Adjustment of the needle mat with the back scraper roller: The clearance between the back stripper roller and the needle mesh and at the same time the desired production amount is adjusted electronically from the control panel. decreases.
4-Needle mat adjustment with the receiving roller: The setting here can be adjusted electronically.
Cleaning of the Machine Before and After the Process
All cleaning work of the machine should only be carried out on the machine that is stopped and secured. In Unimix, the inner surface of the valve and chamber is cleaned with a cotton cloth. With a hand brush between the needle mat and the fly on the chains and gears, the cleaning gun is removed. After the rough cleaning of the spill box is done with brushes, fine cleaning is done with a vacuum cleaner. The covers of the back scraper and the pick-up roller are opened once a week, and visual scanning is performed. The flies accumulated on the chains and gears are cleaned. Mixing chambers and flaps are cleaned once a week, and the fibers accumulated on the surface and edges of the duct conveyor belt rollers are cleaned. Foreign materials in the spill box should be cleaned at the end of each shift.
UNIFLEX MACHINE
Uniflex Cleaning Machine
It is a machine that effectively performs the operations of opening and cleaning the fibers that are blended and opened in the Unimix threshing machine.
Duties
1-Opening the fibers
2-Mixing the fibers
3-To clean foreign materials such as short fiber, dust, seeds and trash in the fiber.
Machine Maintenance
To be able to produce quality products with the machinery and equipment used in the enterprise; In order to be able to work efficiently, smoothly, safely and for a long time with these, machine maintenance techniques should be well known and applied on time.
1- Work accidents will be prevented,
2- The life of the machine will increase,
3- The efficiency of the machine will increase,
4-Operational safety will increase,
5-Energy will be saved,
6- Waste of raw materials will be prevented,
7-Spare parts will be saved.
Machine maintenance is generally done in three ways:
1-Cleaning
2-Daily, weekly, monthly, 6-month and annual maintenance
3-Planned maintenance (renewal)
It is essential to provide a scheduled and periodic maintenance on the threshing room machines. The plan should be made so that monthly maintenance can be done on the threshing machines. Opening cylinder clothings should be checked once a month, bent ones should be corrected, broken ones should be renewed. Oils that come out during lubrication should be cleaned with oakum.
Machine's Settings
1- Thanks to the electronic control, the raw material and the produced product can be adjusted according to all the requirements.
2-The waste separated in the machine can be easily taken for analysis.
3-Due to the single cylinder, negative effects such as neps increase and loss of good fiber encountered in multi-cylinder cleaning systems are minimized.
4-The engine belt is checked twice a week. If it needs to be changed, it is replaced, if it needs to be stretched, it is stretched. Engine transmission oil is changed every 6000 hours.
5-The speed of the cleaning roller and the position of the grill blades are entered electronically from the panel on the machine.
Cleaning of the Machine Before and After the Process
The machine worker cleans the dust, fiber fly, on or around the working machine, between work and when the machine is stopped. Apartment cleaning workers also do their daily and weekly cleaning.
1-The spill chamber should be cleaned in every shift. Machine interior and exterior cleaning should be done at the beginning of each shift.
2-The area around the motor belt should be cleaned.
3-Flies accumulating on the opening roller and the edges of the grills, engine belt and rotating rollers twice a week should be cleaned with a cleaning gun. Surfaces that need to be wiped clean, such as oil stains, are cleaned with diesel oil or kerosene. Never use a mixture of water and detergent. This causes rusting and wear (corrosion).
BLENDING ROOM TRANSPORT SYSTEMS
Transport Systems
It is the system that provides the transfer of fiber from machine to machine in blow room machines. This system has two.
1-With the shipping mat: The fiber is transported between the machines with the help of shipping mats. Although its cost is very cheap, it is a method that is not used today due to the fact that it takes up a lot of space and the material gets dirty during transportation. It is only used in enterprises that mix different materials in the blowroom, and in bale openers, to feed the material to the machine. Today, material delivery in blowroom machines is done by air flow in galvanized pipes with air (pneumatic).
Advantages of this system:
1-It can be mounted in any direction without being bound by a rule in terms of location.
2-Does not cause dust and fiber flying in the blowroom
3-Protects worker health.
4- It is low maintenance and easy to use.
5-Helps open the fiber.
6-The relative humidity of the fiber decreases. This also makes cleaning easier.
Duties
1- To transport fiber between blowroom machines
2-To make the fiber open a little more during shipment
Working Principle
The material sucked by a fan that provides air flow is transmitted to the feeding parts of the machines with galvanized pipes. After the Uniflex machine, light foreign materials and very small dead fibers are separated from the condenser (dust absorber) material (Picture 3.4). In addition, since a smooth layer is formed on the sieve drum, it also provides a partially smooth feeding to the machine it works with. During production, the raw material is passed through the integrated dust separation filter, where dust and fiber fly are cleaned. This cleaning process is carried out in a controlled and effective way with air flow.
Maintenance of Systems
1-Transparent caps on the bends or corners of the delivery pipes should be kept under control. In case of fiber clogging, these caps should be opened and intervened. The inner surfaces of the delivery pipe should be checked manually. There should be no burrs on the surface. Burrs cause clogging.
Systems Settings
If the speed of the air flow in the pipes is less than 15 m/s, it will cause the cotton to collapse and blockages in the pipes. On the other hand, if it is higher than 25 m/s, it causes twining and knots (neps). The length of the delivery pipes should be kept as short as possible, and care should be taken that pipe bends and height differences are not excessive. Otherwise, nep formation increases.
Pre- and Post-Process Cleaning of Systems
The inner surfaces of the pipes must be completely smooth in order to prevent the fiber from getting stuck in the pipes and clogging during the delivery. Thanks to the sheet metal covers placed at critical corners, if clogging occurs, intervention and cleaning becomes easier. Cotton masses propelled by the air flow must be opened to a certain extent so that they can fly more freely.
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