Yarn Manufacture I: Principal of Carding & Drawing

Prof. R. Chattopadhyay
Department of Textile Technology
Indian Institute of Technology, Delhi

Lecture – 19
Draft & Production Calculation

So, today we are going to discuss Production and Draft Calculations. We have already
discussed about draft while discussing carding machine and it was also told to you that
there could be two types of draft mechanical draft and actual draft.

(Refer Slide Time: 00:32)

So, we are going to repeat few things again. So, mechanical draft is the ratio of surface
speeds of front and back rollers that gives us the mechanical draft; that is anyway it tells
us how much is going to be the stretch on sliver, ultimately draft m is a stretching
machine, it is stretching the sliver. So, what is the extent of stretch; that is what is given
by the draft.

You can also find out draft by taking the ratio of linear movement of the back roller and
front rollers in a single revolution of back roller, therefore, the definition of draft, if we
write as it has been written at the bottom the it is the surface speed of front roller divided
by surface speed the back roller or it is a linear movement of front roller per revolution
of the back roller divided by linear movement of the back roller in one revolution, if this
definition is clear to us we will be able to find out mechanical draft very easily. So, you
see in the mechanical draft calculation the linear density or the hank of the sliver does
not come into the picture.

(Refer Slide Time: 02:07)

Now, first let us look at a simple drafting device consisting of 4 pair of rollers therefore,
there are 3 drafting zones and each zone there is a draft of Z 1, Z 2, Z 3, though in the
modern machines there will be mostly 2 zones only, but it does not matter for
understanding let us start with a simple machine where there are 3 zones of drafting. So,
in each zone if we want to find out the draft then how do we go about it. So, here is a
table at the bottom and if you see the table we have mentioned in roller in the column 1
the rotational speed of the rollers, column 2 diameters of the roller and column 3 the
surface speed of the rollers. If we know the diameter of the rotational speed then we can
easily find out the corresponding surface speeds which are stated here.

Therefore draft between front and second roller which is Z 1 will be the ratio of surface
speed. It will be pi n 1 d 1 divided by pi n 2 d 2 and therefore, it is going to be the n 1 d 1
by n 2 d 2 that is the draft in the front zone, similarly we can find out the draft between
second and third roller, it is going to be n 2 d 2 by n 3 d 3 and also we can find out the
draft between third roller and the last roller that is the back roller which is going to be the
n 3 d 3 by n 4 d 4. So, if we do not know the speeds also we will be able to find out draft
that we will see later on, but here to find out draft we need to know the speeds of the
rollers and their diameters and when we try to find out the total draft, total draft Z is the
multiplication of individual drafts Z 1, Z 2, Z 3 and if we put the values of Z 1 Z 2 Z 3
and you will see that n 2 d 2 getting cancelled n 3 d 3 getting cancelled, so therefore, we
are left with n 1 d 1 by n 4 d 4. So, total draft is basically n 1 d 1 by n 4 d 4.

(Refer Slide Time: 04:49)

Now, here there is a diagram on the left hand side of a drafting system and we see there
are 3 pair of rollers front, middle, and back; that means, there are 2 two drafting zones
and they drive from the motor to the different parts of this machine, so the back middle
and front rollers are shown.

Now, if I want to find out the draft in this case we can find it out if you know without
knowing the speed of the individual rollers. So, what will you do we will try to find out
the revolution of the front roller for one revolution of the back roller. So, you will
assume that the back roller as if it is connected through the set of gears and the motion is
going to the front roller. So, we can identify the gears train and which are the gears
which are involved for motion transfer from back to front roller we can look at them and
now if we imagine that a back roller turns by one revolution, what would be in the
number of revolution of the front roller. So, this calculation is shown here 1 into 66 by
109, 109 by 42 131 by 84 and finally 84 by 33. This number indicates the number of
teeth in the gears which are involved in motion transfer between back to front.

Though in the actual case the motion goes from front roller towards the back roller side,
but it does not matter for the calculation of draft. We can assume as if the back roller is
turning the front roller or vice versa also we can do. We can also find out for 1 revolution
of the front roller what is the number of revolution in the back roller both way one can
calculate the draft. So, in this case what the diagram from the diagram what we get that
for one revolution of the back roller the revolutions of the front roller is 6.238; that
means, when the back roller turns by 1 revolution the front roller will be turning by 6.2
revolutions. So, the draft will be how much it will be we can find it out that what is the
linear movement of the back roller and what is the linear movement of the front roller for
1 revolution of the back roller.

So, linear movement of the back roller for 1 revolution will be 1 into pi D BR which is at
the bottom and the linear displacement of the front roller surface for 1 revolution of the
back roller is going to be N into pi D FR or D FR indicates the diameter of the front
roller similarly D BR indicates the diameter of the bottom roller. So, you multiply 6.238
into 35 and also the value of pi will be there and if we do so we will get a where figure
which is 7.79 that is the draft between these 2 rollers or so we can see you can cancel pi
from both numerator and denominator in that case we will be left out with N D FR by D
ER. So, it is going to be 6.238 to 35 by 28 and we get a result which is 7.79 or almost 7.8
that is the total draft between back and front roller.

(Refer Slide Time: 09:25)

The other draft in which will be interested in the break draft that is the draft in the back
zone, it is also known as preliminary draft. So, in that case what we should do; this is
going to be the ratio of displacement of the back and the middle roller surfaces
respectively per revolution of the back roller in the exactly following the same procedure
we will see if the back roller rotates by 1 turn what is going to the rotation of the middle
roller first and then we revolution will be then transformed into linear movement. So, the
diagram is shown here the gear diagram we have to follow that which are the gears
which are involved in this case between back and middle roller and now if we do so we
get this value 1 into 20 by 148 into 143 by 18 and therefore, we get a figure 1.07 that is
the amount of revolution of the middle roller if the back roller turns by 1 revolutions.

Then we take the linear movement and for that we have to multiply by pi also and hence
the break draft is going to be n pi D MR by pi D BR similarly pi and pi cancels in this
case. So, we will be left out with this figure 1.07 into 28 by 28 where 28 millimeters it is
the diameter of the back rollers and the middle roller therefore, break draft in this case is
going to be 1.07. If this is how we can calculate the break draft and the total draft. So, the
front zone draft is will be how much if we multiplied break draft and front zone draft we
get the total draft. So, if we know the total draft if we know the break draft and if I divide
total draft by break draft, then I can see the value up front zone draft or main zone draft
that way we can find out how much draft is there between middle and front roller. (Refer
Slide Time: 11:58)

So, this draft calculation is all based by based on the gears and their number of teeth. In
the calculation the hank of the sliver or the linear density of sliver is not coming in to the
picture, but ultimately it is this sliver which is going to be stretched.
So, what matters to us finally, is the ratio of change in hank or ratio of change in linear
density of the input and the output that is going to be the actual draft. So, in the actual
draft converter how do I calculate the actual draft, the method one from the length of
input and output sliver what we have to do it just from a can remove 6 sliver pieces of 1
meter length first feed this 1 meter sliver pieces together at the back and run the machine
collect the delivered sliver and measures its length find out the length ratio delivered is to
feed length ratio will be the draft because the sliver is going to be stretched. So, 1 meter
sliver will be stretched by 6 meter if the draft is 6 if the draft is 8, 1 meter will be
transformed into 8 meter. So, if we if the input feed length is fixed we check the output
feed length take the ratio that will give us the draft.

(Refer Slide Time: 13:36)

So, this way we can easily calculate the actual draft or method 2 is by taking the ratio of
linear density or hank because in a industrial situation measurement of speed diameters
of the rollers or teeth of the gears may not be always feasible.

In such situations one can find out the linear density of the input and output sliver and
calculate the draft that is what is normally done in the industrial practice. So, if we
follow this particular method then draft is number of doubling of slivers in to inputs
sliver linear density in terms of kilo tex divided by output sliver linear density in kilo tex.
If we do this you can find out what is the actual draft. If the linear density is expressed in
terms of hank that is in English system N e then the draft is going to be count of output
sliver in N e divided by count of input sliver into one upon doubling that is how we
should do the calculations. So, depending upon the units we either follow the first ratio
or otherwise we will follow the ratio second ratio and we can find out the actual draft.

There is another concept this was also told to you while discussing carding that is draft
constant.

(Refer Slide Time: 15:14)

Drafting rollers are driven by a chain of gears; number of teeth of any gear in the chain
can be altered to change the speed ratio between them. If there are n number of gears
which are driving 2 rollers we can change any of those gears and thereby alter the speed
it is very obvious, but in the case of draw frame the machine designers has given the
flexibility to change the teeth of 2 gears, one for total draft change and the other for the
break draft change for altering the total and the break drafts.

So, the way the drive has been designed that if there are n number of gears, there are 2
gears which have been specified this is this has been done by the machine manufacture
and these 2 gears are changeable that is their teeth number of teeth on them can be
changed in order to change the break draft or the main draft. In the calculation of draft
therefore, if the teeth of the changeable gear is considered as a variable then the
numerical value of the ratio of the number of teeth of the gear chain we get in estimating
the draft is the draft constant.
We already have seen that the draft is 1 into so many the teeth of the gears are coming on
the numerator and denominator in that series of numbers which are there you take out the
number which is representing the teeth of the draft chain pinion and rest of the things is
not going to change when you want to change the draft therefore, if we keep that
particular teeth of that particular gear or pinion which is going to change the draft then
whatever value I get that becomes my drafts constant. It can also be stated at the
estimated draft when the teeth in the draft in pinion is considered 1 only, both way we
can define it.

(Refer Slide Time: 17:34)

We have given a calculation for draft constant for this specific case. So, if we see the we
have lifted the previous equation while calculating the draft and put it here and what I
think draft constants equal to 1 into t DCP that is teeth of depth in pinion and then the
series of gears which are there the ratio of their teeth it is shown here.

So, now draft is going to be how much t DCP by 42 into 131 because 109 109 will cancel
84 84 will cancel. So, some of these figures these things will change and you will be left
out with this and we can write draft is going to be 0.118 into teeth of the draft change
pinion which is a variable in this case, but the rest of the gas remains same their teeth
number is not going to change. So, we find out what is the value and that figure is
coming to be 0.118 in this case therefore, the ratio 0118 is known as draft constant in our
case. So, for this particular drive the draft constant is going to be 0.118. So, therefore, the
formula for the draft is going to be 0.118 into teeth of the draft change pinion. So, we can
write that draft is going to be the draft constant K, with that figure is not going to change
into number of teeth of the draft change pinion which is N; therefore Z is going to be k
into N.

(Refer Slide Time: 19:20)

From the draft constant one can easily determine the draft by multiplying draft constant
by number of teeth of the chosen DCP. So, if draft constant is known to me for each and
every machine the draft constant will be fixed and we can easily find out the draft when
we choose a particular change pinion. We just know the number of teeth which are there.
So, we multiplied number of teeth the draft constant we get the draft as an example if we
want choose as a DCP of 57 the draft is going to be 0.118 into 57 that is 6.72. So, this
constant figure is normally noted and for each and every machine and then one can easily
find out the draft for a given change pinion. Sometimes we will be interested to know the
number of teeth of the DCP for a fixing a certain draft. So, sometimes we need to know
the value of N for a given value of Z.

In that case we can write N is going to be Z by K and therefore, 1 upon K is going to be

8.47 that is 1 upon K is 1 divided by 0.118, if we do so, we will get a figure 8.47. So,
8.47 is nothing but 1 by 0.118 this is what is 8.47. So, that multiplied by the draft we will
give me the number of teeth that I required for a given trapped. As an example if I want a
draft of 6.2 the DCP should have teeth how much or how many 8.47 6.2 which gives me
a figure 52.5. So, this is we can take a value either 52 or 53 if I choose a gear which is
close to 52 it will work, a 52 gear it is not available, a 53 is available you can also use 53
because that will make very little error in the draft because we cannot have teeth which is
a decimal figure it has to be always integer 52, 53, 54, or 50 this kind of teeth will
always there in the chain pinion.

And on the right hand side there is a plot between the teeth in DCP that is N versus draft
we get a linear line because Z is going to be K N. So, the equation is a linear equations
all right K indicates the slope. So, draft constant geometrically is in is indicating the
slope of the line which we get when you plot draft against change pinion teeth the slope
indicates the draft constant.

(Refer Slide Time: 23:08)

From draft we move to production calculations, production calculation basics are also
very simple production means we need to know how much length of sliver is delivered
per unit time, this unit time one can decide, it could be if it is per hour one can decide,
one can decide per shift per day it is up to us to decide what is going to be the unit. In
this case plus a part it hour if we decide the length of sliver delivered in meter per 8
hours multiplied by linear density of this sliver in gram per meter, gram per meter is
nothing, but the kilo tex value of the sliver. So, gram per meter if we write it is nothing,
but whatever is the kilo tex value of the sliver that is going to be the gram per meter of
the sliver.
So, if I know how much meter I have delivered and if I know and then you know what is
the weight per meter in gram we multiply these 2, I will get the figure so much gram. I
have produced and then that can be converted into kg also.

(Refer Slide Time: 24:30)

So production in kg per hour per head per 8 hour production in kg per head per 8 hour at
100 percent efficiency so, it will be front roller speed multiplied by pi into roller
diameter millimeter divided by 1000 we want to convert into meter, then multiplied by
60 into 8 hours multiplied by 60 gives me the minute total minute and then sliver linear
density kilo tex by 1000. This is going to give me the production in kg per head per 8
hour. So, front roller speed into power into roller diameter by thousand actually gives me
front roller at delivery in meters per minute. So, if we know the delivery rate in meters
per minute say this is delivery that multiplied by 480 we will give you the total minutes
which are there multiplied by sliver linear intensity kilo tex by 1000 we will give me the
figure in kg.

So, that happens to be 0.48 into front roller delivery into sliver linear density. So, that
becomes the formula to find out the production per head per 8 hour at 100 percent
efficiency. If the sliver count is expressed with English system then this linear density
kilo tex which are there it has to be changed suppose the density is given in any so it will
be 590.5 divided by any that gives the N tex and that has to be converted into kilo tex.
So, we are divided by another 1000 and that gives me a figure finally, which is 0.2834 in
to front roller delivery meters per minute by sliver linear density in any. So, this way also
we can find out what is going to be the production per head per 8 hour.

(Refer Slide Time: 26:43)

Here as an example, you have taken the same diagram and want to find out what is the
delivery rate, for this particular problem or diagram delivery rate is going to be motor
speed that is speed of the motor pulley and then motor pulley diameter by machine
pulley diameters and then we have to go through the gearings to find out what is going to
be the delivery rate of the front roller.

So, if we do so we get these figures that is 1440 is the speed of the motor then 270 and
165 these are the diameter of the motor pulley and the machine pulley and then rest is the
teeth of the gear train which is driving the front roller. So, finally, we go to the front
roller through all these gear trains and the figure that we get is 258.9 meters per minute.
This calculation you can do yourself also because here all this are canceling and will be
left out like this. So, the delivery rate is going to be around in this case 259 meters per
minute in today’s you know standard its very low speed.
(Refer Slide Time: 28:25)

So, if I produce a sliver of let us say 5 kilo tex then how much is going to be the
production per hour per head is going to be 258.9 there is a delivery rate into 5 kilo tex
sliver and 1 hours 5 into 60 and gram a converted into kg, so divided by 1000, we get a
figure 77.67 kg. So, that is going to be the production rate of the draw frame per head per
hour. So, it is per hour per head if there are most of the machines are 2 head machines in
that case from both the heads will get double the production.

So, we have to multiply 77.67 in multiplied by 2 that gives me 155.34 that becomes the
production per hour from a 2 head machines and if I want per shift with 100 percent
efficiency I have to multiplied by a figure which is 7.5 because we have assumed in this
case that is shift of 8 hours 30 minutes is the recess time and though most of the time in
the industry the machine runs continuously and anyway if I assume that in a shift 7.5
hours the machines are running then I get a figure that I multiplied 155.34 into 7.5 and
you get a figure 1165 kilo; that means, you draw frame in this particular case is
producing 1165 kg of material per shift, the delivery rate is on the lower side the modern
draw frames we will learn at 500 600 meters per minute, it all depends upon the type of
fibers that you are possessing.
(Refer Slide Time: 30:35)

Now, during a shift the machine may remain idle for short or long time due to many
reasons. So, we have already stated that we are finding out the production at 100 percent
efficiency, but the machines may not run at 100 percent efficiency due to many reasons;
like one is can changing time once the cans get filled up the can is replaced full can is
replaced by an empty can. So, there is some time which is lost production time is lost
could be lost in the modern machine with they are trying to overcome this, mind not
cleaning sometimes we stop the machine for some cleaning operations sliver breaks on
the creels a machine stops and it becomes idle for some time.

There is a possibility of roller lapping again the machine we will stop because you have
to protect the machine the whenever there is a lapping there is a stop motions which will
stop the machine, there is a sensor which will sense and the machine will be stopped and
till the lapping is removed the machine remains idle. So, some production time is lost,
there could be trumpet choking also that can also lead to idle time for the machine.

Shortage of heat can in some cases that we have to feed 8 cans behind the machine if
there is shortage of 1 can and we will not be able to run the machine. So, this problem
also could be there, and the last problem could be power failure which is also possible.
So, there are many reasons which can lead to idle time for the machine and therefore, the
efficiency or the production that we expect theoretically we may not get that production
actually; therefore, efficiency is defined as actual production divided by theoretical
production into 100.

(Refer Slide Time: 32:44)

So, theoretical production is based on the gears, numbers, and the calculation that we
have already seen. Actual production may come less than that take this ratio multiplied
by 100 that gives me the efficiency figure. Efficiency of a draw frame lies between 75 to
85 percent and depending upon the mixing of the fibers; that is how the machine runs
and actual production therefore, could be theoretical production into whatever is the
efficiency percentage divided by 100 that we will give me.

So, actual production in this case 0.48 into front roller delivery sliver linear density
which we have find out earlier that into the efficiency figure we have to now put into the
equation and then only we will get what is the actual production. The other thing that we
are going to discuss is the canned filling time.
(Refer Slide Time: 33:50)

How much time it takes to fill up a can it all depends upon the can capacity and the
production rate per head. So, filling time is going to be the ratio of can capacity divided
by production rate per head in kg per hour and that multiplied by 60 minutes to convert
the time into minute. For an example, in the capacity of a can draw frame can is 22 kilo
machine is producing at a rate of 80 kg per hour then the filling time is going to be 16.5
minutes that is every 16.5 minutes a can is going to be filled by the sliver. So, every 15,
16 sixteen minutes can will be full with sliver and we have to replace the full can by a
empty can. So, we can expect that in an hour that could be 4 replacement roughly in 1
head, in 2 head there is going to be 8 replacement and if there is a time is lost during this
replacement of can, loss of production.
(Refer Slide Time: 35:04)

The other thing which will be interested to know the how much length of sliver is there
in a can; how to find it out it is also very simple straightforward calculations suppose the
empty can weight is w Kg, full can weight is x kg. So, the weight of sliver is going to be
w minus x kilo. If this sliver linear density is S in terms of kilo tex then the length of
sliver is going to be w minus x by s into 1000 meter. As an example let us say the weight
of sliver 22 kilo the sliver linear density is 5.5 kilo tex then how much sliver is there in
the can 22 by 5.5 into 1000. So, that will give me. So, this 5.5 is coming is as gram per
meter. So, you have to convert this into kg. So, therefore, 5.5 by 1000 is coming this
1000 is going up in the numerator. So, you get 22 in to 1000 divided by 5.5 and that is a
meter that multiplied by 1000 so, that gives me 4000 meter of material.

So, how much it is giving that in a can we have almost 4000 meter of sliver on an
average this is going to be there. So, we convert this or we can say we can convert the
weight of the material which is in kg into gram first. So, 22 by 1000 gives the weight in
gram. This is gram per meter that multiplied give so many meters and that convert it into
a value which is 4000 meter. So, we will get roughly 4000 meter of sliver in a can. With
this we close this calculation part of production and draft.

Thank you.