Relationship between production control and rubber roller apron quality

The influence of the hardness, thickness, elasticity, life cycle, dispersion and rubber quality of the rubber roller and rubber ring on the spinning quality is often the focus of academic papers or academic seminars. It is well known that rubber will age with the prolonged use time, and the wear during operation will cause the surface of the rubber roller to be uneven, the hardness is increased, the elasticity is decreased, and the unevenness of the apron is intensified, resulting in a decrease in the dry C value of the cotton yarn, and various variations. The CV value increased, the details, thick sections, and neps gradually increased, and harmful yarn defects at all levels increased significantly. Extending the service life of rubber rollers and aprons is a major issue that manufacturers need to solve. It can increase the service life of rubber materials by improving the quality and processing technology of rubber materials, reduce the unevenness and wear generated during the spinning process, and prevent different individuals and batches. There is a large difference in quality between the rubber roller and the rubber ring.

 

 

 

After investigating the use of new and old rubber rollers and rubber rings in the same rubber factory for hundreds of textile mills for a long time, a large number of statistics and analysis were carried out on rubber rollers and aprons with wear, scratches, grooves and irregularities. In the Nanyang of Henan Province, five spinning mills were randomly selected. Among them, 100% of the rubber rollers and rubber rings in each of the four spinning mills were related to human factors. The relative number of mid-shift and night shift injuries was relatively high. Only one textile factory glue 98% of the damage of rollers and aprons is caused by human factors; the data analysis of dozens of textile factories in Xinjiang also shows that the proportion of rubber roller and rubber ring damage caused by human factors reaches 100%. Therefore, the textile mill strengthens the management of textile equipment, reduces the damage and damage of the rubber roller and the rubber ring, and achieves the purpose of reducing the cost and improving the overall quality consistency of the cotton yarn. It has also been found that more than 95% of sporadic yarn defects related to rubber roller and apron problems are caused by human factors, especially night shifts. The number of damages and damages is 5 to 10 times that of white shifts, which should be 4 hours. The textile mills that operate and produce strengthen the management of midnight shifts, and develop a stricter and more reasonable system than the white shifts to manage the medium and night shift spinning equipment and control the quality of cotton yarn.

 

 

 

Rubber roller, apron damage, groove marks, wear, unevenness, oil stains, cracks, rubber hose slippage from the bearing, rubber ring breakage, etc., 99% are caused by the lack of management in the production control process, so the production workshop should Formulate the transfer of the rubber roller and the apron, the operation class and the maintenance maintenance handover system. Analysis of the causes of rubber roller, apron damage, damage and the establishment of a reward and punishment system is the key to effectively prevent human factors from causing damage and damage to rubber rollers and aprons; in addition, the current textile mills have difficulty in survival, difficulty in recruiting workers, and a large number of new workers. The existence of many problems such as short time, as well as the actual situation of human factors damage, damage to rubber rollers and aprons, and the rational use and treatment of rubber rollers and rubber rings in the production workshop are the key points to protect the quality of rubber rollers and aprons. It is also the key to reducing the production cost of textile mills and improving the consistency of cotton yarn quality.

 

 

 

Effect of winding treatment method on the quality of rubber roller

 

 

 

The rubber roller and the apron winding are mainly caused by the difference in the quality of the rubber material, the antistatic treatment is not in place, the processing rubber roller and the apron process are poorly controlled; in addition, the spinning raw material has sugar, high wax content and air conditioning. The temperature and humidity control is poor, and the management of the workshop is not in place. The management of the production workshop is not in place, which is also the key reason for the scattered winding of rubber rollers and rubber rings. Generally speaking, the large area rubber roller and rubber ring winding of the textile factory is caused by the rubber quality and the temperature and humidity control of the textile factory air conditioner, and the sporadic winding is basically caused by the internal management of the spinning mill. The treatment method after the rubber roller and the rubber ring are wounded is the main factor affecting the quality of the rubber roller and the rubber ring. Common rubber roller and apron winding treatment methods include: centralized replacement, hooking knife to remove the entangled cotton wadding during the operation of the equipment, manual removal of the rubber roller, apron treatment of the entangled cotton wool, and treatment of the adhesive wadding with a cleaning tool. Among them, the most harmful is the hook knife treatment, which is easy to cause damage to the rubber roller and rubber ring, resulting in a large number of sporadic yarn defects; the use of cleaning tools to handle the winding rubber roller and rubber ring during operation will also cause glue Scratches or abrasions of rollers and aprons cause sporadic sporadic yarn defects in cotton yarns; when the shop management is not in place, the winding rubber rollers and rubber rings are replaced, which are prone to different batches, thicknesses and hardnesses. Mix and match, make various variations and yarn defects in cotton yarn, this work should be done by professional rubber roller staff. Separately removing the cotton wool from the rubber roller and the apron wound by the single spindle can reduce the damage and damage of the rubber roller and the rubber ring, and can check whether it needs to be replaced, and prevent the rubber roller and the rubber ring from being mixed; The precondition of the treatment method is that the same batch of rubber roller and rubber ring of the same quality must be provided in the production workshop, which is beneficial to prevent the occurrence of sporadic yarn defects and various variations of cotton yarn.

 

 

 

The development of modern rubber technology makes the control of rubber dispersion, elasticity, static electricity and the control of temperature and humidity of textile mills easier to realize. There are few large-scale rubber rollers and rubber rings wound in the spinning mills. Therefore, local equipment and local areas of textile mills The winding of sporadic rubber rollers and aprons is a problem that textile mills need to control and solve. The rubber roller and rubber ring wound by the single production control method are enough to cause serious damage to the quality of the cotton yarn; the correct and effective control method for controlling the rubber roller and the rubber ring winding can not only reduce the damage and damage of the rubber roller and the rubber ring. It can also stabilize the quality of cotton yarn and reduce the defects of cotton yarn.

 

 

 

Table 1 is a summary of the processing of the rubber roller and the rubber ring in a different manner in the spinning process of the 10 million spinning mill, 30d, resulting in damage and damage of the rubber roller and the rubber ring. The statistical data in Table 1 shows that: centralized replacement treatment is one of the best ways to prevent rubber roller and rubber ring damage, damage, cracking and cracking; using hook knife treatment is rubber roller, rubber ring damage, damage, crack, The main factors of cracking and cracking are recommended for the spinning mill to use centralized treatment and single spindle manual treatment.

 

 

 

Table 2 is a summary of the number of early, middle and night rubber rollers, apron winding damage and damage in the spinning process of a 100,000 spindle spinning mill.

 

 

 

The statistical data in Table 2 shows that from morning shift to mid-shift to night shift, the number of rubber roller and rubber ring damage and damage has doubled, and the number of night shifts is about 6-8 times that of early shift, which proves that the production management of night shifts is relaxed. Therefore, it is necessary to strengthen the production management control of the middle and night shifts. This is the key point for textile mills to prevent damage and damage to equipment and equipment, and is also the key to stabilizing the quality of cotton yarn.

 

 

 

Influence of bearing cleaning and refueling on the quality of rubber roller aprons

 

 

 

The effect of cleaning and refueling of rubber roller bearings and roller bearings on rubber rollers and aprons is easily neglected. The refueling of rubber roller bearings in textile mills is not quantified by any hand, and it is easy to cause the bearing lubricants to run during operation. The overflow causes the rubber roller and the rubber ring to be stained with oil. The same is true for the roller bearing. The refueling during maintenance or the maintenance of the three-way mechanics causes the roller to overflow or splash a lot during the operation, which not only pollutes the roller, but also causes serious contamination and entanglement of the rubber roller and the rubber ring, so that the rubber roller The rubber ring is eroded by oil from the surface to the inside, resulting in aging cracks in the early operation process, which makes it easier to adsorb the short fibers generated by the flying and spinning of the workshop, forming a large number of rubber rollers and aprons. Damage, damage. Even if the spinning mill strengthens the rubber roller and the rubber ring in the later stage, it is difficult to clean the oil that has been soaked in the rubber roller and the rubber ring, which seriously affects the effective operation of the rubber roller and the rubber ring, and becomes the main cause of oil stains and defects in the cotton yarn. factor.

 

 

 

Improve the refueling method of the rubber roller bearing of the spinning mill, control the refueling amount, and ensure that the rubber roller does not overflow during the operation. It is one of the effective methods to protect the rubber roller and the rubber ring from corrosion, soaking, damage and damage; The grease type of the bearing oil, the amount of oil, the number of times the tanker is squeezed is the key to reduce rubber roller, rubber ring pollution, damage, damage, cracking and cracking; different greases are used for different spinning equipment and roller bearings. Model and refueling method are also one of the methods to prevent rubber roller and rubber ring pollution. Strictly control the amount of fuel, the rubber roller and roller bearing after refueling have no oil spill in the 24h operation. It is the best refueling effect. If the rubber roller bearing and the roller bearing have a small amount of oil spill during operation, it must be quickly cleaned to prevent pollution. Rollers, rubber rollers, aprons and upper pins.

 

 

 

Table 3 is a summary of the fuel quantity of 1000-pin rubber roller and roller bearing in a 50,000-spinning spinning mill in 7d and the contamination, entanglement, damage and damage of rubber roller and rubber ring.

 

 

 

 Table 3 shows the statistical data: rubber roller bearings and roller bearings are too much oil, not only the number and frequency of rubber roller and rubber ring increase, but also the number of windings increases, and the number of damage and damage increases sharply. Therefore, controlling the refueling amount of the rubber roller bearing and the roller bearing not only prevents the above problems, but also stabilizes the quality of the cotton yarn and reduces the defects of the cotton yarn.

 

 

 

Influence of cleaning frequency of drafting and winding parts on the quality of rubber roller aprons

 

 

 

During the long-term research and technical service guidance for textile mills, we found that the quality of spinning raw materials, equipment and spinning equipment was emphasized from the leaders of spinning mills to the operating shifts and equipment sections of the production workshops. Spinning technology, air conditioning and equipment maintenance and maintenance, they are considered to be the key to affect spinning equipment, spinning technology, spinning quality, most people are not aware of equipment, drafting parts, winding parts to glue The influence of rollers and aprons.

 

 

 

Manufacturers producing high-grade cotton yarns, low-grade high-quality cotton yarns, and general-numbered high-quality carded cotton yarns, in addition to pursuing cotton yarn production and controlling certain quality, regardless of the quality of blended cotton and the quality of air-conditioning dust removal Good or bad, the equipment, spinning equipment, drafting parts, winding parts are still cleaned and preserved according to the traditional frequency. As a result, various coefficient of variation of cotton yarns is increasing, and cotton yarn defects are difficult to control, resulting in various types of spinning. Equipment and spinning equipment are damaged or damaged to varying degrees. In the process of technical improvement and improvement, the author found that the spinning mill, which pays more attention to the quality of spinning equipment, spinning equipment and spinning raw materials, as well as the cleaning frequency of drafting parts, winding parts and production workshops, The frequency of scratches, abrasions, cracks, cracks, and shedding of rollers and aprons is very low, about 10% to 15% of manufacturers who do not pay attention to these factors. That is to say, if the cleaning frequency of the normal 10,000 spindle spinning mill is more than 300, the damage and damage of the rubber roller and the rubber ring are 300, and the cleaning frequency is less or abnormal. Will reach 3,000 to 4,500. According to the calculation of 3 yuan per rubber roller, the spinning mill with less cleaning frequency or abnormality will cause economic loss of 0.9 million to 13,500,000 yuan. At the same time, various quality problems caused by insufficient cleaning frequency of cotton yarn are especially occasional. The problem of yarn defects will reduce the price of cotton yarns of the same number and the same production cost by 1,000 yuan/t to 3,000 yuan/t; if the output of the combed 18.2tex cotton yarn produced by the spinning mill in one month is 140t, then clean The frequency of normal or more spinning manufacturers will be more than 140,000 yuan / month to 520,000 yuan / month than the manufacturers with abnormal cleaning frequency or less. This is reflected in the difference in the value of cotton yarn than in rubber rollers and glue. The difference in losses on the circle is 10 to 30 times. Therefore, no matter what method, the frequency of cleaning of spinning equipment, spinning equipment, drafting parts and winding parts should be strengthened. This not only improves the service life of related equipment and equipment, but also reduces the damage of rubber rollers and aprons. Damage can not be ignored. The frequency of cleaning must be determined comprehensively according to the spinning quality requirements, the type of spinning, the condition of the equipment, and the dust removal condition. Otherwise, the equipment, spinning equipment, drafting parts, winding parts will be damaged, and the quality of the cotton yarn will be seriously damaged and the spinning cost will be increased. .

 

 

 

Table 4 shows the CJ29.2tex cotton yarn produced by 10,000 spindles in a 50,000 spinning mill. The cleaning frequency of the spinning process and the damage and damage of the rubber roller and the rubber ring are summarized.

 

 

 

Table 4 shows the statistical data: the number of cleaning and winding parts increases with the number of cleanings per day, and the probability of flying flowers and rubber rollers and aprons is reduced. The degree of damage to the rubber rollers and rubber rings is severely reduced. The increase of the number and the improvement of the quality requirements of the cotton yarn, the winding of the rubber roller, the apron, the damage and the damage are more obvious, and it is necessary to increase the cleaning frequency of the drafting and winding parts; the summary results indicate that the drafting and rolling are performed in the production of the general number of cotton yarns. The damage of the rubber roller and the rubber ring is 2 times per part of the cleaning of the parts, and the damage is only 10% to 20% of the cleaning once a day. It proves that the number of cleaning of the drafting and winding parts is reasonable and the cleaning frequency is appropriately increased, which is to ensure the rubber roller and glue. The important part of the complete spinning of the ring is also an important part of reducing the quality of the cotton yarn and stabilizing the quality of the cotton yarn.

 

 

 

The effect of changing the rubber roller apron on the quality of the production workshop

 

 

 

The increase in the scale of the production workshop of the textile mill is not conducive to the management of the use of rubber rollers and aprons. At present, a production workshop of a spinning mill has a scale of 50,000 spindles, 60,000 spindles, 10 million spindles, 130,000 spindles, and 160,000 spindles. This workshop produces several or more than ten cotton yarn varieties, which need to be used with each. Rubber rollers and aprons of different hardnesses, different thicknesses and different times of grinding have brought a lot of inconvenience to the management of rubber rollers and aprons. Damage and damage of rubber rollers and rubber rings will occur at any time. Even with replacement rubber rollers and rubber rings, it is impossible to avoid the use of rubber rollers and rubber rings of different hardnesses, different grinding times and different thicknesses on the same spinning equipment. Large-scale spinning workshops with good management, although they are all marked by markings, when they are processed in a certain or a certain area of ​​the spinning machine rubber roller and rubber ring, they will still find a mixture, not to mention the poor production management of the workshop. In the large workshop, the use of rubber rollers and rubber rings is even more mixed. It is even possible to find colorful rubber rollers and rubber rings on a spinning machine of a certain area or a certain area. What is even more terrible is that the diameter of the rubber roller will appear on the same spinning frame. A difference of 3mm, 4mm, the use of 3 or more years of aprons, rubber roller, apron damage, cracks and cracks everywhere, this is the result of poor replacement of rubber roller, apron mode. Therefore, for a large-scale spinning workshop, establishing a strict and uniform standardized replacement mode is the key to preventing the chaotic use of rubber rollers and rubber rings. Although many spinning mill rubber rollers and apron processing chambers have different spare rubber rollers and rubber rings for different varieties of spinning workshops, so that they can be replaced by midnight shifts, but they do not take into account the consumption of rubber rollers and rubber rings by different varieties. Different, different machines use the rubber roller and rubber ring with different thickness, number of grinding times and hardness. When the difference is large, changing the rubber roller and rubber ring will cause large deviation and variation of cotton yarn quality. Therefore, large-scale production vehicles should appropriately reduce the variety of cotton yarns, avoid diversified production, strictly implement regional control and control of spinning machines, strengthen equipment maintenance and maintenance, and strengthen the inspection and handover of spinning rubber rollers and rubber rings. The key to mixing rubber rollers and rubber rings.

 

 

 

Table 5 is a summary of the mixed use of rubber rollers and rubber rings in the spinning workshop of different scale spinning mills for one month.

 

 

 

Table 5 shows the statistical data: whether it is rubber roller or rubber ring, when the production workshop scale is controlled at 30,000 spindles, it is beneficial to the consistency control of rubber roller and rubber ring; when the spinning workshop scale reaches 50,000 spindles as unit or above At the time of use, the number of occurrences of mixing is multiplied; the larger the size of the production plant, the larger the number of rubber rollers and aprons used, the worse the consistency, and the greater the chance of damage and damage. In the modern spinning workshop of multi-variety and multi-machine, controlling the unit size of the spinning workshop production workshop is the key to ensure the quality control of product diversity, and also the key to control the consistency of spinning equipment. The number of spinning spindles in the production workshop unit of the spinning mill is increasing, which not only increases the difficulty of production management in the workshop, but also increases the spinning equipment and spinning.