How to Improve the Layout of Top Roller Equipment Through Tight Spinning
Source: China Bearing Network | Time: 2013-10-25
According to data from the 2001 Uster Bulletin, which analyzed 40 combed cotton yarns, the 5% level of ring spinning and the 95% level of tight spinning are considered optimal. The advantages of tight spinning yarn are highly significant. In China, tight spinning has become a key factor in the textile industry's development, with many industry experts believing that it will eventually replace traditional ring spinning. Jingwei Co., Ltd. and SUESSEN have signed a cooperation agreement for tight spinning technology, aiming to promote localized production. This article provides an analysis of the experience gained in the development of SUESSEN’s Elite tight spinning equipment, particularly focusing on the layout improvements of the top roller components. Improvement of Component Layout The tightly-spun upper roller component is one of the most precise parts in the entire tight spinning system. Each part must meet extremely high precision standards. The upper roller is fixed by two upper and lower casings, with drafting occurring at positions 1, 2, and the gear transmission mechanism. Position 2 of the top roller is driven by position 1 through gears. Several key improvements have been made to the roller assembly: Firstly, the joint housing was redesigned from an open type to a sealed structure. This ensures that the gear transmission system is fully enclosed, reducing the need for frequent maintenance and improving sealing efficiency. Instead of internal seals, a labyrinth seal is used between the gear and the positioning ring, enhancing bearing protection. Secondly, the outer diameter of the top roller at position 2 has been significantly increased, allowing it to completely cover the suction port of the shaping tube. This helps maintain consistent yarn flow and reduces defects. Thirdly, the gear transmission system now includes two main gears and a bridge gear. By increasing the diameter of the rubber roller at position 2, the draw ratio is improved, extending the lifespan of the gears. Lastly, the rubber roller in the tight-spinning upper roller component is made using an aluminum bushing without any additional coating. This increases surface roughness, enhancing grip and performance. Misunderstanding of Bearing Clearance Bearing clearance in the top roller is a major concern for both spinning mills and manufacturers. Many domestic mills believe that the clearance directly affects yarn unevenness and mechanical waves. Especially during the production of cyanide rubber rollers, the quality of the bearing is often judged based on this factor. Some manufacturers have misled mills into thinking that smaller or no clearance bearings are better, leading to incorrect assumptions about bearing quality. However, when using aluminum bushings without sleeves, a slight difference of 0.03 mm to 0.06 mm is necessary to ensure proper bonding between the rubber roller and the bearing outer ring. If the bearing itself has a small or no clearance, the rubber roller may not rotate smoothly, causing issues such as jamming or poor performance, which can lead to waste and reduced product quality. To address this issue, we conducted random sampling and pressure matching experiments. The results showed that the radial clearance should not be less than 0.006 mm. Reducing the clearance further leads to unresponsive bearings, affecting the overall performance of the system. Long-Term Bearing Protection Maintaining clean and lubricated bearings in the leather roller room is a challenging and time-consuming process. Regular cleaning and refueling are required, and if not done properly, it can lead to sticky yarn and damage to the bearings. JW-SUESSEN’s Elite tight-spinning top roller equipment features a protection-free design. This eliminates the need for frequent maintenance, such as refueling and cleaning. The device uses a long-lasting, smooth grease that can last up to 60,000 operating hours, effectively providing lifelong protection for the bearings. Feasibility of Localization Importing tight spinning systems is expensive, and while China has developed its own spinning techniques, there is still a need for more affordable and efficient solutions. Localizing the production of tight spinning equipment could significantly reduce costs and improve accessibility. In our trial manufacturing of tight spinning roller equipment, we found that the cost of localized equipment is approximately 120 yuan, which is much lower than imported alternatives. Domestic producers already possess advanced skills, and the demand for tight spinning is being well met. Therefore, the localization of tight spinning equipment is a practical and necessary path forward. It not only reduces costs but also accelerates the adoption of tight spinning technology, contributing to the advancement of China’s textile industry.
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