Staple Fiber Spinning can be Optimally Implemented Using Automation Solutions and Products from Siemens

Staple Fiber Automation - Main

Staple fibers are still the backbone of the textile industry. Whether pure cotton or joint fabric, “yarn“ is still for the most part manufactured using conventional spinning procedures. This commences with the fabric supplied in bales made of cotton or synthetic fiber. Via the process chain including bale opener, tuft feeder, mixer, carding machine, drawing machine and combing machine, the actual spinning process is executed.

Much has changed during recent decades. Added to the conventional ring spinning process, further procedures such as compact spinning and rotor spinning are also used. Special effects for “fancy yarn“ can also be achieved in production.

The complicated interaction of different drives and transmission elements in modern yarn production places high demands on drives and automation. Single axis solutions and intelligent drive concepts in combination with Siemens controllers form a consistent concept.

With an automation solution from Siemens, you will benefit from

  • Suitability for Use in the Spinning Room
    via flow-through or coldplate cooling

  • Cost-Effective Total Solution
    through proven, customized products/systems and optimized automation of the machine

  • Low Space Requirements and Reduced Number of Components
    with compact converter and dual-axis modules through multi-axis drive control


Carding Machine

Staple Fiber Automation - Carding Machine

The carding machine is located in the spinning process between the blow room and the drawing frame. It cleans and parallelizes the fibers. The resulting card web is then formed into a tape and placed into a can. The working elements are taker-in, main cylinder, card top and doffing cylinder. The working elements are equipped with saw-tooth wires. In addition to several general advantages Siemens solutions for carding machines help you optimize your production results through

  • High availability with Siemens global support

  • Reduced spare parts and service costs through a consistent range of drives


Solution Example

Driving the main units requires between 3 and 5 drive motors, including about 3 servo motors:
1 motor 11-15 kW for the main cylinder; 3 motors 0.5 kW for taker-in and doffing cylinder, corresponding drives.

Staple Fiber Animation - Carding

Siemens Products Used

A

SIMATIC HMI

B

SIMATIC ET 200SP Distributed IO

C

PROFINET Industrial Communication

D

SIMOTION D Drive-Based Motion Controller
SINAMICS S120 Servo Drives

E

SIMOTICS M Induction Motors

F

SIMOTICS S Servo Motors


Drawing Frame

Staple Fiber Automation - Drawing Frame

On their way to become high-quality yarn, staple fibers must first be subjected to extensive processing. The drawing frame is located in the spinning process between the carding machine and the spinning machine. It serves to draw out and parallelize the fibers. In this process, the drawing frame is a major quality driver, since all flaws that are preserved in the drawn fiber structure will also become visible in the yarn. Major components of the drawing frame include the feeding gate, the drawing equipment and the take-off cylinder.

Siemens offers a high-quality solution to meet the automation solution challenges. SIMOTION and SINAMICS products support a sophisticated automation concept that provides many benefits for the machine.

Solution Example

The automation serves to ensure the accurate speed synchronism of the four drives - especially during the start and stop of the machine and in case of power failure. The Motion Control system SIMOTION D and the drive system SINAMICS S offer a fully integrated automation solution from a single source.

Staple Fiber Automation - Drawing Frame

Siemens Products Used

A

SIMATIC HMI

B

SIMATIC ET 200SP Distributed IO

C

PROFINET Industrial Communication

D

SIMOTION D Drive-Based Motion Controller
SINAMICS S120 Servo Drives

E

SIMOTICS S Servo Motors

Benefits

  • Optimum Production Results
    through high-speed material thickness control (with closed-loop controlled system)

  • Superior Control Dynamics
    with differential gearbox
    or

  • Direct Control
    using a highly dynamic servo motor


Combing Machine

Staple Fiber Automation - Combing Machine

The combing machine, whose use is optional, to improve the yarn quality, is located in the spinning process between the drawing frame and the flyer. Its goal is achieved by combing out the shorter fibers, thus increasing the effective fiber length. Siemen solutions for combing machines offer

  • Individual drive for the pilgrim step motion

  • High drive dynamics


Solution Example

The minimum requirements are 1 servo motor for the feeder (Mn approx. 6 Nm) and 1 asynchronous motor for the rotary comb as the main drive (approx. 7.5 kW).
Both motors are located on the drive.

Staple Fiber Automation - Combing Machine

Siemens Products Used

A

SIMATIC HMI

B

SIMATIC ET 200SP Distributed IO

C

PROFINET Industrial Communication

D

SIMOTION D Drive-Based Motion Controller
SINAMICS S120 Servo Drives

E

SIMOTICS S Servo Motor with Resolver

F

SIMOTICS S Servo Motor with Encoder


Flyer

Staple Fiber Automation - Flyer

The flyer, located in the spinning process between the drawing frame and the ring spinning frame, produces a suitable roving for the ring spinning frame. The already-drawn fiber tape is further drawn out in the flyer. Major components of the flyer are the feeding gate, the drawing equipment, and the flyer frame.

Solution Example

Usually 4 motors are required on the drive. An asynchronous motor with about 11 kW is used for the drawing equipment, while one servo motor each is used for the lifting motion, the flyer wings and the spindles (MO approx. 18-36 Nm).

Staple Fiber Automation - Flyer

Siemens Products Used

A

SIMATIC HMI

B

SIMATIC ET 200SP Distributed IO

C

PROFINET Industrial Communication

D

SIMOTION D Drive-Based Motion Controller
SINAMICS S120 Servo Drives

E

SIMOTICS S Servo Motors

F

SIMOTICS M Main Induction Motors

Benefits - High Productivity, through

  • Multi-axis control

  • Minimum setup times

  • Electronic gear factor presets


Ring Spinning Frame

Staple Fiber Automation - Ring Spinning Frame

In the last step of yarn production, the staple fibers are fed to the ring spinning frame, after passing through the blow room (opening and cleaning) and the carding frame, drawing frame and flyer (separation of individual fibers, parallelization, formation of a fiber tape). Here, the finished yarn is produced by drawing and rotating operations.

Solution Example

The modular innovative concept of the ring spinning frame from Siemens ensures the easy and fast takeover of the machine parameters when changing to other yarn types and guarantees consistently high and reproducible yarn qualities. The drawing equipment is implemented with 3 individual drives, and the spindles are combined in several groups per drive.

Staple Fiber Automation - Ring Spinning Frame

Siemens Products Used

A

SINAMICS Web Server

B

SIMOTION Web Server

C

PROFINET Industrial Communication

D

SIMATIC ET 200SP Distributed IO

E

SIMOTION D Drive-Based Motion Controller
SINAMICS S120 Servo Drives

F

SIMOTICS S Servo Motors

G

SIMOTICS M Main Induction Motors

H

SIRIUS Commanding and Signaling Devices

Benefits - High Productivity, through

  • Multi-axis control

  • Minimum setup times

  • Electronic gear factor presets


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