Maintenance in Rotor Spinning

rotor spinning maintenance

Maintenance in Rotor Spinning
Prajwal Patil, Janamjay Narwaria
Department of Textile Technology
DKTE Engineering College, Kolhapur, Maharashtra
Introduction:
Rotor spinning is also called as break spinning. In any industry the performance of the machine plays an important role in order to determine the productivity. Productivity is effective utilization of man, power and machine. Hence in order to keep machine in good condition there is a need of good maintenance activity. Hence the maintenance activity of rotor spinning is explained in the following article.

Components of total productive maintenance:-

Preventive Maintenance: Preventive maintenance is performed regularly on equipment so that their should not be any sudden break down. It is performed while the equipment is still working so that it does not break down unexpectedly.

Corrective Maintenance:- Corrective maintenance is a maintenance task performed to identify, isolate, and rectify a fault so that the failed equipment, machine, or system can be restored to an operational condition within the tolerances or limits established for in-service operations.

Predictive Maintenance: It is the technique to predict the future failure points of a machine component. So that the component can be replaced, based on the plan just before it fails.

Lubricants:-
There are 2 types of lubricants on the basis of viscosity:
Oil
Grease

Importance of Lubricants:-
Reduction of wear & tear reduces machine maintenance time & cost
Legibility assurance of m/c & m/c parts.
Higher operating efficiency less idel time & stopping.
Reduces fatigue & boredom of work forces due to well running less stoppage & troubles.
Develop ergonomic & improve working environment.

Working & Schedule of maintenance rotor machine:-

Cleaning Task weekly

Sr.no
Components
Location
Task
1.
Light barrier B30/B31
Light barrier B502/B503
Package conveyor belt package lift tube loader UNIfeed
Cleaning of fibre fly, primarily in the active area. Use only soft rugs and brushes
2.
Rotor
Spinning Position
Spot checks: dirt build-up and caked dirty residue on the rotor shaft

Cleaning Task, every 1.5 months
Sr.no
Components
Location
Task
1.

By pass filter in the main filter box
Foot end
Only when main switch is off!
Open flap on air duct or clean filter screen of fibre fly & duts.
2.
Motors
Headstock Foot end
Only when the main switch is off!
Remove fly and dust particles from motor ventilation covers.
3.
Track robot Drag chain robot
Headstock section foot end
Remove fly and dust particles
4.
Trash conveyor belt right and left

Only when the conveyor belts are not running
5.
Frequency inverters
Headstock Foot end
Vaccum off contamination like dust dirt, and fibres
6.
Fibre channel and channel plate, nozzle, delivery tube, By pass
Spinning position
Open opening unit do not reach into the vicinity of the opening roller drive
Clean with compressed air
Clea nozzle from the nozzle
7.
Opening unit
Opening roller
Opening through
Spinning position
Only when main switch is off!
Clean if required.

Maintenance, every 6 months
Sr.no
Components
Location
Task
1.
Travers rod in front of top rollers.
Section
If movement is Jerky: clean track rollers with the machine standing, to achieve smooth running
2.
Package Lifting
Spinning Position
Check distance between package and winding roller immediately after stopping m/c
3.
Connecting level
Spinning unit
Check for damage and replace if required.
4.
Rotor
Spinning Position
Check for - defects ( rotor groove, rotor sliding wall)
Condition of mark, stil visible
5.
Opening unit
Opening roller
Spinning Position
Only when main switch is off!
Clean whorl on opening roller, plastic bearing bedge on trash extraction point and exit-edge of channel into opening unit
6.

Winding roller, cylindrical and conical
Spinning Position
For high package quality std. Depends on when cot worm to 75mm

Maintenance, every 1 year
Sr.no
Component
Location
Task
1.
Shaft's
Headstock
Oil change, using gear oil CC 68 400cm^3
2.
Yarn traverse gear box
Headstock
Oil change, using gear oil CC 68 5800cm^3
Or 2800cm^3
3.
Delivery shafts
Winding shaft
Section
Regrease 16 lubrication nipples per section, using multi-purpose grease K3, 2.5cm^3 each

Maintenance Schedule According Time.
Sr.no
Component
No.of Worker Required
Time Required
1.
All machine and robots cleaning
      1
   120 min
2.
Machine general cleaning
     5
   480 min
3.
Spinning area cleaning
     2
   240 min
4.
Robot cleaning by soap water
    2
   240 min
5.
Replacement of gear box oil
    2
   120 min
6.
Replacement of rotor belt
   2
   240 min
7.
All points general greasing
  2
   120 min
8.
Refilling of gearbox oil
  2
    240 min
9.
 Delivery and winding roller greasing
  2
    240 min
10.
Monoblock, Deflection roller greasing
  1
    120 min

Conclusion:
The care and servicing by personal for the purpose of maintaining equipment in satisfactory operating condition by providing for systematic inspection, detection, and correction of incipient failures either before they occur or before they develop into major defects.

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