EP3327184A1 - Rotor spinning method and device for four-sliver asynchronous inputting and three-level carding - Google Patents

Rotor spinning method and device for four-sliver asynchronous inputting and three-level carding Download PDF

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Publication number
EP3327184A1
EP3327184A1 EP15901885.2A EP15901885A EP3327184A1 EP 3327184 A1 EP3327184 A1 EP 3327184A1 EP 15901885 A EP15901885 A EP 15901885A EP 3327184 A1 EP3327184 A1 EP 3327184A1
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European Patent Office
Prior art keywords
carding
yarn
rollers
roller
speed
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EP15901885.2A
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German (de)
French (fr)
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EP3327184B1 (en
EP3327184A4 (en
Inventor
Weidong Gao
Yuan XUE
Mingrui GUO
Ruihua YANG
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Jiangnan University
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Jiangnan University
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    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01HSPINNING OR TWISTING
    • D01H4/00Open-end spinning machines or arrangements for imparting twist to independently moving fibres separated from slivers; Piecing arrangements therefor; Covering endless core threads with fibres by open-end spinning techniques
    • D01H4/04Open-end spinning machines or arrangements for imparting twist to independently moving fibres separated from slivers; Piecing arrangements therefor; Covering endless core threads with fibres by open-end spinning techniques imparting twist by contact of fibres with a running surface
    • D01H4/08Rotor spinning, i.e. the running surface being provided by a rotor
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01HSPINNING OR TWISTING
    • D01H4/00Open-end spinning machines or arrangements for imparting twist to independently moving fibres separated from slivers; Piecing arrangements therefor; Covering endless core threads with fibres by open-end spinning techniques
    • D01H4/30Arrangements for separating slivers into fibres; Orienting or straightening fibres, e.g. using guide-rolls
    • D01H4/32Arrangements for separating slivers into fibres; Orienting or straightening fibres, e.g. using guide-rolls using opening rollers
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01HSPINNING OR TWISTING
    • D01H4/00Open-end spinning machines or arrangements for imparting twist to independently moving fibres separated from slivers; Piecing arrangements therefor; Covering endless core threads with fibres by open-end spinning techniques
    • D01H4/42Control of driving or stopping
    • D01H4/44Control of driving or stopping in rotor spinning

Definitions

  • the present invention relates the field of rotor spinning in the textile industry.
  • the basic principle of the rotor spinning yarn is that the sliver is fed through the trumpet and is held by feeding plate and a feeding roller.
  • the feeding roller rotates to feed the sliver to the carding area.
  • the sliver is opened and stripped, carded separately and mixed by the carding roller, which is rotating at a high speed in the carding area, so that the sliver becomes single fibers which are separated and arranged in parallel to each other.
  • the single fibers enter into a fiber transport channel. Under the action of air flow, the fiber flows into the rotor through the fiber transport channel. Under the centrifugal force of the rapidly rotating rotor, the fibers in the collection groove are further piled up and mixed, and then the fibers are jointed with the mother-yarn and twisted by a navel to form a yarn.
  • the patent Method and equipment for rotor spun slub yarn can achieve invariable blending ratio but the linear density changes during the rotor spinning process.
  • the principle of the patent is that the asynchronous motor and the stepper motor drive feeding roller through the differential, screw and worm wheel.
  • the stepper motor under the control of the intelligent controller, performs the following operations: reducing from high speed to low speed; continuing to run for a period of time; accelerating to high speed; continuing to run for a period of time, and the rotor spins a segment of slub yarn.
  • the patent can produce a yarn with variable densities but cannot change blending ratios of the yarn.
  • the production of the yarn with the linear density and blending ratio both changed requires not only that the feeding amount of the two or more of the fed roving can be controlled separately on line, but also that the total amount of the fed roving can be controlled when the feeding amount the roving is changed. There is no patent that can achieve the production of such yarn.
  • the main problem of the existing rotor spinning technology which can produce the yarn having an invariable linear density and blending ratio is that it is impossible to blend two or more fibers in any proportion during the rotor spinning process.
  • a device for implementing a rotor spinning method with three-level carding and multi-component feeding includes a spinning system and a computer control system.
  • the spinning system comprises a feeding and carding mechanism, a collecting and twisting mechanism, and a winding mechanism.
  • the device is characterized in that the feeding and carding mechanism comprises a three-level carding roller and a combined feeding roller having four rotational freedom degrees. The speed ratio of the four combined feeding rollers with rotational freedom degree can be adjusted.
  • the collecting and twisting mechanism includes a fiber transport channel, a rotor, and a drafting device.
  • the winding mechanism includes a couple of guide rollers and a winding mechanism.
  • the computer control system includes a PLC programmable controller, a servo driver, a servo motor.
  • the four combined feeding rollers with rotational freedom degrees and the three-level carding roller are driven by the servo motor.
  • the combined feeding rollers with four rotational freedom degrees comprises a shaft, a bearing, a hollow shaft, a first gear, a second gear, a third gear, a fourth gear, a washer, a first movable roller, a second movable roller, a third movable roller, and a fourth movable roller.
  • the first gear, the second gear, the third gear, the fourth gear, the first movable roller, the second movable roller, the third movable roller, and the fourth movable roller rotate around the same axis.
  • the first to the fourth gears respectively drive the first to the fourth movable rollers.
  • the three-level carding roller comprises the first carding roller, the second carding roller and the third roller, arranged in parallel.
  • the rotation speed of the three-level carding roller is progressively increased from the first level to the third level.
  • the rotation speed of the first carding roller is 1500-3000 rpm
  • the rotation speed of the second carding roller is 3000-6000 rpm
  • the rotation speed of the third carding roller is 6000-12000 rpm.
  • the density of carding needles of the three-level carding roller progressively increases from the first carding roller to the third carding roller..
  • the other objective of the present invention is to provide a rotor spinning method using the above device.
  • the method includes cotton feeding, carding, collecting and twisting, guide and winding.
  • the method is characterized in that combined feeding rollers with four rotational freedom degrees are used in the fiber feeding to feed the fiber into the carding area asynchronously, and three-level carding roller is used in the carding process.
  • four slivers (or four different raw material slivers, or four kinds of colored slivers, hereinafter referred to as four components) can be asynchronously fed into the rotor spinning and carding area through the combined feeding rollers.
  • the two slivers After opening, carding, orienting, separating and mixing by the three-level carding roller, the two slivers are gradually combed into bundle fibers and further combed into single fibers. Under the action of centrifugal force and air flow, a continuous flow comprised by single fibers, released and transferred from the carding roller, enters into the rotor rotating at a high speed.
  • the fiber flow In the rotor, the fiber flow, under the centrifugal force, is collected together into a sliver again, and then twisted by the navel, and then guided by the guide roller to form the rotor spinning yarn.
  • the servo driving system is controlled by a computer program to feed four slivers asynchronously to the carding area by feeding rollers having four freedom degrees. By controlling the feeding amount and feeding ratio of the four feeding rollers, it is possible to dynamically configure the final yarn density of the rotor spinning and the blending ratio of the four components to produce slub yarn, segment-color yarn, segment-color slub yarn, and mixture yarn.
  • the speed of the first carding roller is low, so that it is ensured that when the plurality of the slivers with great difference are fed, the total number of carding fibers of each sliver carded by the carding roller is within a reasonable range, thereby reducing damage to the fiber.
  • the speed of the second carding roller is higher than that of the first carding roller. After being carded by the second carding roller, the longitudinal orientation of the fiber is optimized, horizontal transfer mixing of the fiber is further optimized.
  • the third carding roller is a high-speed carding roller. The fiber, after being carded by the third carding roller, obtains not only a better carding and transfer, but also the transport speed is improved, thereby meeting the requirement of centrifugal force for entering the fiber transport channel.
  • the fiber can smoothly and orderly go into the rotor to form yarns.
  • the large-scale drafting function where the slivers are combed into web, which is then combed into bundles of fibers, which are then separated as single fibers is successfully completed, which enhances the function of the carding area of the rotor spinning, providing flexibility, high efficiency, and high yield.
  • the present invention constructs the corresponding mathematical model of spinning and the algorithm of the program.
  • the mechatronic servo control system Through the mechatronic servo control system, the random control of the linear density and blending ratio of the rotor spinning yarn are achieved.
  • the four kinds of spinning yarns are shown as following:
  • Subscripts 1, 2, 3, 4 respectively represent component A, component B, component C, component D.
  • the fiber holding time of each component is also greatly different.
  • the rotation speed of the single carding roller is high. Therefore, when there is a significant difference in feeding amount, the number of times that a fiber of the four slivers is carded will be significantly different, and the more the fiber experiences carding, the larger will be the damage to this fiber.
  • the present invention adopts the form of three-level carding rollers, that is, the first carding roller, the second carding roller and the third carding roller.
  • the large-scale drafting function where the slivers are combed into web, which is then combed into fiber bundles, which are separated into single fibers, is successful completed, which enhances the function of the carding area of the rotor spinning, meets the special requirements for the carding of multiple slivers asynchronously feeding into the rotor spun unit.
  • the effects of flexibility, high efficiency, and high yield are realized.
  • E 2 V 2
  • V 1 ⁇ 11 + ⁇ 21 + ⁇ 31 + ⁇ 41 ⁇ 12 + ⁇ 22 + ⁇ 32 + ⁇ 42
  • E 3 V 3
  • V 2 ⁇ 12 + ⁇ 22 + ⁇ 32 + ⁇ 42 ⁇ 11 + ⁇ 23 + ⁇ 33 + ⁇ 43
  • E 5 V 5
  • K 1 ⁇ 1 V 01 ⁇ 1 V 01 + ⁇ 2 V 02 + ⁇ 3 V 03 + ⁇ 4 V 04
  • K 2 ⁇ 2 V 02 ⁇ 1 V 01 + ⁇ 2 V 02 + ⁇ 3 V 03 + ⁇ 4 V 04
  • K 3 ⁇ 3 V 03 ⁇ 1 V 01 + ⁇ 2 V 02 + ⁇ 3 V 03 + ⁇ 4 V 04
  • K 4 ⁇ 4 V 04 ⁇ 1 V 01 + ⁇ 2 V 02 + ⁇ 3 V 03 + ⁇ 4 V 04 ⁇ 4 V 04 ⁇ 1 V 01 + ⁇ 2 V 02 + ⁇ 3 V 03 + ⁇ 4 V 04
  • V 03 ' V 03 + ⁇ V 03
  • Mixed configuration is gradient to realize different color scheme.
  • V 01 , V 02 , V 03 , and V 04 the blending ratio (color mixing ratio) of different fibers (different colors) in the yarn can be changed under the condition that V 0 is kept invariable, so that k 1 , k 2 , k 3 , and k 4 are changed between 0 - 100%.
  • the minimum increment of the color mixing ratio is 0.1, wherein one of the color schemes is as follows: Table 1 color scheme color A color mixing ratio k 1 color B color mixing ratio k 2 color C color mixing ratio k 3 color D color mixing ratio k 4 Color code Monochromatic color A 1 0 0 0 1 color B 0 1 0 0 2 color C 0 0 1 0 3 color D 0 0 0 1 4 AB 0.1 0.9 0 0 5 0.2 0.8 0 0 6 0.3 0.7 0 0 7 0.4 0.6 0 0 8 0.5 0.5 0 0 9 0.6 0.4 0 0 10 0.7 0.3 0 0 11 0.8 0.2 0 0 12 0.9 0.1 0 0 13 AC 0.1 0 0.9 0 14 0.2 0 0.8 0 15 0.3 0 0.7 0 16 Double-color 0.4 0 0.6 0 17 mixing 0.5 0 0.5 18 0.6 0 0.4 0 19

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Preliminary Treatment Of Fibers (AREA)
  • Spinning Or Twisting Of Yarns (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Coloring Foods And Improving Nutritive Qualities (AREA)

Abstract

A multi-level carding rotor spinning method and device. The device includes a spinning system and a computer control system. The spinning system includes a feeding and carding mechanism, a collecting and twisting mechanism, and a winding mechanism. The feeding and carding mechanism includes combined feeding rollers (2-5, 2-6, 2-7, 2-8) having four rotational freedom degrees and multiple levels of carding rollers (2-10, 2-11, 2-12). The speed ratio of four rollers of the combined feeding rollers having four rotational freedom degrees can be adjusted, so that the linear density and the blending ratio of rotor spun yarns are randomly adjusted.

Description

    Technical field
  • The present invention relates the field of rotor spinning in the textile industry.
  • Background
  • The basic principle of the rotor spinning yarn is that the sliver is fed through the trumpet and is held by feeding plate and a feeding roller. The feeding roller rotates to feed the sliver to the carding area. The sliver is opened and stripped, carded separately and mixed by the carding roller, which is rotating at a high speed in the carding area, so that the sliver becomes single fibers which are separated and arranged in parallel to each other. The single fibers enter into a fiber transport channel. Under the action of air flow, the fiber flows into the rotor through the fiber transport channel. Under the centrifugal force of the rapidly rotating rotor, the fibers in the collection groove are further piled up and mixed, and then the fibers are jointed with the mother-yarn and twisted by a navel to form a yarn.
  • In the Patent "Rotor spinning melange yarn forming method and device and product (Application No. CN201410190891.1 )" and" Device of spinning rotor spun melange yarn ( CN201420229715.X )", the speed of the feeding roller is controlled to keep feeding in a invariable amount, or two or more drawn silvers are fed in segments in different amounts, resulting in that the blending ratio has monochromatic or multi-colored fibers mixture, so as to achieve an effect that the blending ratio can be adjusted while the density of the spun yarn is invariable. However, these two inventions have two problems. First, in these inventions, only the concept of realizing the blending and segment-color spinning process with invariable linear density through the proposed coupling and drafting method, and no indication is given to show how to change the mixing ratio or color blending ratio under the condition that the coupling and drafting achieves an invariable linear density. In the meantime, no specific embodiments and examples are disclosed. Second, a conventional single carding roller is still used in those patent applications. When three slivers are fed at the same time, the original carding and drafting system cannot adequately strip, card, separate and mixt a plurality of slivers, which will cause inadequate break down of fiber strands, resulting in blocking the carding roller and rotor, and will be prone to yarn broken and slub, nep and other defects. At the same time, although the total amount of each sliver by coupling and feeding is invariable, there is still a difference in the feeding amount of each sliver, and the short carding area causes little chance of horizontal fiber mixing, resulting in unsatisfactory color blending effect.
  • At present, the patent Method and equipment for rotor spun slub yarn" (patent number CN00137211.4 ) can achieve invariable blending ratio but the linear density changes during the rotor spinning process. The principle of the patent is that the asynchronous motor and the stepper motor drive feeding roller through the differential, screw and worm wheel. The stepper motor, under the control of the intelligent controller, performs the following operations: reducing from high speed to low speed; continuing to run for a period of time; accelerating to high speed; continuing to run for a period of time, and the rotor spins a segment of slub yarn. The patent can produce a yarn with variable densities but cannot change blending ratios of the yarn.
  • The production of the yarn with the linear density and blending ratio both changed requires not only that the feeding amount of the two or more of the fed roving can be controlled separately on line, but also that the total amount of the fed roving can be controlled when the feeding amount the roving is changed. There is no patent that can achieve the production of such yarn. The main problem of the existing rotor spinning technology which can produce the yarn having an invariable linear density and blending ratio is that it is impossible to blend two or more fibers in any proportion during the rotor spinning process.
  • Summary of the Invention
  • In order to solve the above problem, the present invention improves the structure of the conventional rotor spinning machine. A device for implementing a rotor spinning method with three-level carding and multi-component feeding, includes a spinning system and a computer control system. The spinning system comprises a feeding and carding mechanism, a collecting and twisting mechanism, and a winding mechanism. The device is characterized in that the feeding and carding mechanism comprises a three-level carding roller and a combined feeding roller having four rotational freedom degrees. The speed ratio of the four combined feeding rollers with rotational freedom degree can be adjusted. The collecting and twisting mechanism includes a fiber transport channel, a rotor, and a drafting device. The winding mechanism includes a couple of guide rollers and a winding mechanism. The computer control system includes a PLC programmable controller, a servo driver, a servo motor. The four combined feeding rollers with rotational freedom degrees and the three-level carding roller are driven by the servo motor. The combined feeding rollers with four rotational freedom degrees comprises a shaft, a bearing, a hollow shaft, a first gear, a second gear, a third gear, a fourth gear, a washer, a first movable roller, a second movable roller, a third movable roller, and a fourth movable roller. The first gear, the second gear, the third gear, the fourth gear, the first movable roller, the second movable roller, the third movable roller, and the fourth movable roller rotate around the same axis. The first to the fourth gears respectively drive the first to the fourth movable rollers. The three-level carding roller comprises the first carding roller, the second carding roller and the third roller, arranged in parallel. The rotation speed of the three-level carding roller is progressively increased from the first level to the third level. The rotation speed of the first carding roller is 1500-3000 rpm, the rotation speed of the second carding roller is 3000-6000 rpm, and the rotation speed of the third carding roller is 6000-12000 rpm. The density of carding needles of the three-level carding roller progressively increases from the first carding roller to the third carding roller..
  • The other objective of the present invention is to provide a rotor spinning method using the above device. The method includes cotton feeding, carding, collecting and twisting, guide and winding. The method is characterized in that combined feeding rollers with four rotational freedom degrees are used in the fiber feeding to feed the fiber into the carding area asynchronously, and three-level carding roller is used in the carding process.
  • With the combined rollers and the three-level carding roller configured in the present invention, four slivers (or four different raw material slivers, or four kinds of colored slivers, hereinafter referred to as four components) can be asynchronously fed into the rotor spinning and carding area through the combined feeding rollers. After opening, carding, orienting, separating and mixing by the three-level carding roller, the two slivers are gradually combed into bundle fibers and further combed into single fibers. Under the action of centrifugal force and air flow, a continuous flow comprised by single fibers, released and transferred from the carding roller, enters into the rotor rotating at a high speed. In the rotor, the fiber flow, under the centrifugal force, is collected together into a sliver again, and then twisted by the navel, and then guided by the guide roller to form the rotor spinning yarn. In the process of spinning, the servo driving system is controlled by a computer program to feed four slivers asynchronously to the carding area by feeding rollers having four freedom degrees. By controlling the feeding amount and feeding ratio of the four feeding rollers, it is possible to dynamically configure the final yarn density of the rotor spinning and the blending ratio of the four components to produce slub yarn, segment-color yarn, segment-color slub yarn, and mélange yarn.
  • The speed of the first carding roller is low, so that it is ensured that when the plurality of the slivers with great difference are fed, the total number of carding fibers of each sliver carded by the carding roller is within a reasonable range, thereby reducing damage to the fiber. The speed of the second carding roller is higher than that of the first carding roller. After being carded by the second carding roller, the longitudinal orientation of the fiber is optimized, horizontal transfer mixing of the fiber is further optimized. The third carding roller is a high-speed carding roller. The fiber, after being carded by the third carding roller, obtains not only a better carding and transfer, but also the transport speed is improved, thereby meeting the requirement of centrifugal force for entering the fiber transport channel. Therefore, the fiber can smoothly and orderly go into the rotor to form yarns. Through the multi-level stripping, opening, cleaning, carding, separating, and transferring, the large-scale drafting function where the slivers are combed into web, which is then combed into bundles of fibers, which are then separated as single fibers is successfully completed, which enhances the function of the carding area of the rotor spinning, providing flexibility, high efficiency, and high yield.
  • (2) Based on the mechanical innovation design, the present invention constructs the corresponding mathematical model of spinning and the algorithm of the program. Through the mechatronic servo control system, the random control of the linear density and blending ratio of the rotor spinning yarn are achieved. In specific embodiments, the four kinds of spinning yarns are shown as following:
    • ① a yarn with invariable linear density and variable blending ratio, such as gradient-color or segment-color yarn with an invariable linear density segment;
    • ② a yarn with invariable blending ratio and variable linear density, such as slub yarn, big-belly yarn, dot yarn;
    • ③ a yarn with variable linear density and variable blending ratio, such as segment-color slub yarn, segment-color big-belly yarn, segment-color dot yarn;
    • ④ a yarn with invariable linear density and invariable blending ratio but mixed with any proportion of blended yarn or color-mixed yarn.
    Brief description of the drafting s
    • FIG.1 is a flowchart of the rotor spinning.
    • FIG.2 is a diagram of the carding and drafting process of the rotor spinning method with three-level carding roller.
    • FIG.3 is a diagram showing the transmission of the feeding roller, wherein.3b is the right-side view of 3a.
    • FIG.4 is a structural view of the combined feeding roller.
    • FIG.5 is a diagram of a spinning control system with four components asynchronous fed and carded
    • FIG.6 is a diagram of a control model of a rotor spinning yarn system with four components asynchronous input.
      • 1-1, 1-2, 1-3: carding roller; 1-4, 1-5: trash ejection port; 1-6: feeding roller; 1-7: sliver; 1-8: compression spring; 1-9: feeding plate; 1-10: fiber transport channel; 1-11: navel; 1-12: rotor; 1-13: degassing hole; 1-14, 1-15: guide roller, 1-16: yarn;
      • 2-5, 2-6, 2-7, 2-8: feeding roller; 2-1, 2-2, 2-3, 2-4: sliver; 2-9: feeding plate; 2-10, 2-11, 2-12: carding roller; 2-13: fiber flow; 2-14: rotor; 2-15: yarn;
      • 3a-5, 3a-6, 3a-7, 3a-8: rollers; 3a-1, 3a-2, 3a-12, 3a-13: gears; 3a-3, 3a-4, 3a-9, 3a-10: idler gear; 3a-11: roller shaft; 3a-14, 3a-15, 3a-16: carding roller, 3a-17: spun yarn, 3b-1: gear; 3b-2: roller; 3b-3, 3b-4, 3b-5, 3b-6: gears;
      • 4-1, 4-2, 4-3, 4-4: rollers; 4-5, 4-6, 4-12, 4-15: gears; 4-7, 4-11, 4-14: key; 4-8: fixed shaft sleeve; 4-9: screw; 4-10: bearing; 4-13: shaft. Four movable rollers (4-1, 4-2, 4-3, 4-4) are driven by the gears (4-5, 4-6, 4-12, 4-15) respectively.
    Detailed description of the Invention
  • The meaning of the formula used in the text:
    • V01: linear velocity of the feeding roller 1; V02: linear velocity of the feeding roller 2; V03: linear velocity of the feeding roller 3; V04: linear velocity of the feeding roller 4; V1: the linear velocity of the carding roller 1; V2: the linear velocity of the carding roller 2; V3: the linear velocity of the carding roller 3; V4: the linear speed of the rotor; V5: the linear velocity of the guide roller.
    • ρ1: linear density of sliver A (g / m)
    • ρ2: linear density of sliver B (g / m)
    • ρ3: linear density of sliver C (g / m)
    • ρ4: linear density of sliver D (g / m)
    • ρ: yarn density (g / m);
    • ρ11: linear density of the sliver A passing through the carding roller 1 (g / m)
    • ρ12: linear density of the sliver A passing through the carding roller 2 (g / m)
    • ρ13: linear density of the sliver A passing through the carding roller 3 (g / m)
    • ρ14: linear density of the sliver A in the rotor (g / m)
    • ρ21: linear density of the sliver B passing through the carding roller 1 (g / m)
    • ρ22: linear density of the sliver B passing through the carding roller 2 (g / m)
    • ρ23: linear density of the sliver B passing through the carding roller 3 (g / m)
    • ρ24: linear density of the sliver B in the rotor (g / m)
    • ρ31: linear density of the sliver C passing through the carding roller 1 (g / m)
    • ρ32: linear density of the sliver C passing through the carding roller 2 (g / m)
    • ρ33: linear density of the sliver C passing through the carding roller 3 (g / m)
    • ρ34: sliver C linear density in the rotor (g / m)
    • ρ41: linear density of the sliver D passing through the carding roller 1 (g / m)
    • ρ42: linear density of the sliver D passing through the carding roller 2 (g / m)
    • ρ43: linear density of the sliver D passing through the carding roller 3 (g / m)
    • ρ44: linear density of the sliver D in the rotor (g / m)
    • E1: draft ratio of the carding roller 1 to the feeding roller;
    • E2: draft ratio of the carding roller 2 to the carding roller 1;
    • E3: draft ratio of the carding roller 3 to the carding roller 2;
    • E4: draft ratio of the rotor to the carding roller 3;
    • E5: draft ratio of the guide roller to the rotor;
    • E: The total draft ratio of rotor spinning, which is equal to the draft ratio of the guide roller to the feeding roller.
  • Subscripts 1, 2, 3, 4 respectively represent component A, component B, component C, component D.
  • (1) three-level roller carding process design:
  • As to feeding a plurality of the slivers, when the feeding speeds of feeding rollers are greatly different, the fiber holding time of each component is also greatly different. In the rotor spinning with single carding roller, due to the need of balancing the stripping /carding fibers, as well as the requirement of the fiber speed when transferring to the fiber transport channel, the rotation speed of the single carding roller is high. Therefore, when there is a significant difference in feeding amount, the number of times that a fiber of the four slivers is carded will be significantly different, and the more the fiber experiences carding, the larger will be the damage to this fiber.
  • In order to solve the problem of the rotation speed of the carding roller against the damage to fiber and the even mixture of fibers, the present invention adopts the form of three-level carding rollers, that is, the first carding roller, the second carding roller and the third carding roller. The rotation speed of the first carding roller (ω = 1500-3000rpm) is relatively low, the needle density is relatively low, the working angle of the needle is relatively small. It is mainly configured for stripping, opening, cleaning and carding and focusing on making the total carding number of fibers of each sliver within a reasonable range, thereby reducing damage to the fiber. The speed of the second carding roller (ω = 3000-6000rpm) is mainly configured for stripping, carding and transferring fibers, wherein the needle density is also larger than the needle density of the first carding roller, and the working angle of the needle is relatively larger than that of the first carding roller. After being carded by the second carding roller, the longitudinal orientation of the fiber is optimized, and horizontal transfer mixing of the fiber is further optimized. The third carding roller is a high-speed carding roller (ω =6000-12000 rpm), which is mainly configured for stripping, carding and separating, and transferring fibers, wherein the needle density is larger than the needle density of the second carding roller, and the working angle of the needle is largest. Fibers passing through the third carding roller gets better carding and transfer. Furthermore, due to the high speed of the third carding roller, under the action of centrifugal force and air flow, a highly separated and continuous fiber flow passes through the fiber transport channel and enters orderly into the rotor to form yarns.
  • Through the stripping, opening, cleaning, carding, and transfer of the three-level carding roller, the large-scale drafting function, where the slivers are combed into web, which is then combed into fiber bundles, which are separated into single fibers, is successful completed, which enhances the function of the carding area of the rotor spinning, meets the special requirements for the carding of multiple slivers asynchronously feeding into the rotor spun unit. The effects of flexibility, high efficiency, and high yield are realized.
  • (2) Draft ratio of the rotor spun yarn:
  • E 1 = ρ 1 + ρ 2 + ρ 3 + ρ 4 V 1 ρ 1 V 01 + ρ 2 V 02 + ρ 3 V 03 + ρ 4 V 04 = ρ 1 + ρ 2 + ρ 3 + ρ 4 ρ 11 + ρ 21 + ρ 31 + ρ 41
    Figure imgb0001
    E 2 = V 2 V 1 = ρ 11 + ρ 21 + ρ 31 + ρ 41 ρ 12 + ρ 22 + ρ 32 + ρ 42
    Figure imgb0002
    E 3 = V 3 V 2 = ρ 12 + ρ 22 + ρ 32 + ρ 42 ρ 11 + ρ 23 + ρ 33 + ρ 43
    Figure imgb0003
    E 4 = V 4 V 3 = ρ 13 + ρ 23 + ρ 33 + ρ 43 ρ 14 + ρ 24 + ρ 34 + ρ 44
    Figure imgb0004
    E 5 = V 5 V 4 = ρ 14 + ρ 24 + ρ 34 + ρ 44 ρ
    Figure imgb0005
    E = E 1 E 2 E 3 E 4 E 5 = ρ 1 + ρ 2 + ρ 3 + ρ 4 V 5 ρ 1 V 01 + ρ 2 V 02 + ρ 3 V 03 + ρ 4 V 04 = ρ 1 + ρ 2 + ρ 3 + ρ 4 ρ
    Figure imgb0006
    E = ρ 1 + ρ 2 + ρ 3 + ρ 4 V 5 ρ 1 V 01 + ρ 2 V 02 + ρ 3 V 03 + ρ 4 V 04 = ρ 1 + ρ 2 + ρ 3 + ρ 4 ρ
    Figure imgb0007
  • (3) The linear density of rotor spun yarn
  • ρ = ρ 1 V 01 + ρ 2 V 02 + ρ 3 V 03 + ρ 4 V 04 V 5
    Figure imgb0008
  • (4) Blending ratio
  • The blending ratios of components A, B, C, D in the rotor spinning yarn are K1, K2, K3, and K4 respectively: K 1 = ρ 1 V 01 ρ 1 V 01 + ρ 2 V 02 + ρ 3 V 03 + ρ 4 V 04
    Figure imgb0009
    K 2 = ρ 2 V 02 ρ 1 V 01 + ρ 2 V 02 + ρ 3 V 03 + ρ 4 V 04
    Figure imgb0010
    K 3 = ρ 3 V 03 ρ 1 V 01 + ρ 2 V 02 + ρ 3 V 03 + ρ 4 V 04
    Figure imgb0011
    K 4 = ρ 4 V 04 ρ 1 V 01 + ρ 2 V 02 + ρ 3 V 03 + ρ 4 V 04
    Figure imgb0012
  • (4) Dynamic linear density of rotor spun yarn
  • Assuming that the speed V5 of the guide roller is invariable, the variables of feeding speed V01, V02, V03, and V04 of the four slivers are respectively as follows: V 01 ' = V 01 + Δ V 01
    Figure imgb0013
    V 02 ' = V 02 + Δ V 02
    Figure imgb0014
    V 03 ' = V 03 + Δ V 03
    Figure imgb0015
    V 04 ' = V 04 + Δ V 04
    Figure imgb0016
    So that the new changed linear density of the rotor spun yarn is ρ ' = ρ 1 V 01 + Δ V 01 + ρ 2 V 02 + Δ V 02 + ρ 3 V 03 + Δ V 03 + ρ 4 V 04 + Δ 04 V 5 = ρ 1 V 01 + ρ 2 V 02 + ρ 3 V 03 + ρ 4 V 04 V 5 + ρ 1 Δ V 01 + ρ 2 Δ V 02 + ρ 3 Δ V 03 + ρ 4 Δ V 04 V 5
    Figure imgb0017
    Δρ= ρ 1 Δ V 01 + ρ 2 Δ V 02 + ρ 3 Δ V 03 + ρ 4 Δ V 04 V 5
    Figure imgb0018
  • (5) Dynamic blending ratio of the rotor spun yarn is:
  • Assuming that: ρ1 = ρ2 = ρ3 = ρ4 = ρ0 V 01 + V 02 + V 03 + V 04 = V 0
    Figure imgb0019
    Reference blending ratios are shown as below: K 1 = V 01 V 0
    Figure imgb0020
    K 2 = V 02 V 0
    Figure imgb0021
    K 3 = V 03 V 0
    Figure imgb0022
    K 4 = V 04 V 0
    Figure imgb0023
    When V01+V02+V03+V04→V01+ΔV01+V02+ΔV02+V03+ΔV03+V04+ΔV04, the blending ratio become as below: K 1 ' = V 01 + Δ V 01 V 0 + Δ V 0
    Figure imgb0024
    K 2 ' = V 02 + Δ V 02 V 0 + Δ V 0
    Figure imgb0025
    K 3 ' = V 03 + Δ V 03 V 0 + Δ V 0
    Figure imgb0026
    K 4 ' = V 04 + Δ V 04 V 0 + Δ V 0
    Figure imgb0027
    Mixed configuration is gradient to realize different color scheme.
  • By changing V01, V02, V03, and V04, the blending ratio (color mixing ratio) of different fibers (different colors) in the yarn can be changed under the condition that V0 is kept invariable, so that k1, k2, k3, and k4 are changed between 0 - 100%. In various color mixing modes of four primary colors, the minimum increment of the color mixing ratio is 0.1, wherein one of the color schemes is as follows: Table 1 color scheme
    color A color mixing ratio k1 color B color mixing ratio k2 color C color mixing ratio k3 color D color mixing ratio k4 Color code
    Monochromatic color A 1 0 0 0 1
    color B 0 1 0 0 2
    color C 0 0 1 0 3
    color D 0 0 0 1 4
    AB 0.1 0.9 0 0 5
    0.2 0.8 0 0 6
    0.3 0.7 0 0 7
    0.4 0.6 0 0 8
    0.5 0.5 0 0 9
    0.6 0.4 0 0 10
    0.7 0.3 0 0 11
    0.8 0.2 0 0 12
    0.9 0.1 0 0 13
    AC 0.1 0 0.9 0 14
    0.2 0 0.8 0 15
    0.3 0 0.7 0 16
    Double-color 0.4 0 0.6 0 17
    mixing 0.5 0 0.5 18
    0.6 0 0.4 0 19
    0.7 0 0.3 0 20
    0.8 0 0.2 0 21
    0.9 0 0.1 0 22
    AD 0.1 0 0 0.9 23
    0.2 0 0 0.8 24
    0.3 0 0 0.7 25
    0.4 0 0 0.6 26
    0.5 0 0 0.5 27
    0.6 0 0 0.4 28
    0.7 0 0 0.3 29
    0.8 0 0 0.2 30
    0.9 0 0 0.1 31
    BC 0 0.1 0.9 0 32
    0 0.2 0.8 0 33
    0 0.3 0.7 0 34
    0 0.4 0.6 0 35
    0 0.5 0.5 0 36
    0 0.6 0.4 0 37
    0 0.7 0.3 0 38
    0 0.8 0.2 0 39
    0 0.9 0.1 0 40
    BD 0 0. 1 0 0.9 41
    0 0.2 0 0.8 42
    0 0.3 0 0.7 43
    0 0.4 0 0.6 44
    0 0.5 0 0.5 45
    0 0.6 0 0.4 46
    0 0.7 0 0.3 47
    0 0.8 0 0.2 48
    0 0.9 0 0.1 49
    CD 0 0 0.1 0.9 50
    0 0 0.2 0.8 51
    0 0 0.3 0.7 52
    0 0 0.4 0.6 53
    0 0 0.5 0.5 54
    0 0 0.6 0.4 55
    0 0 0.7 0.3 56
    0 0 0.8 0.2 57
    0 0 0.9 0.1 58
    0.1 0.1 0.8 0 59
    0.1 0.2 0.7 0 60
    0.1 0.3 0.6 0 61
    0.1 0.4 0.5 0 62
    0.1 0.5 0.4 0 63
    0.1 0.6 0.3 0 64
    0.1 0.7 0.2 0 65
    0.1 0.8 0.1 0 66
    0.2 0.1 0.7 0 67
    0.2 0.2 0.6 0 68
    0.2 0.3 0.5 0 69
    Tricolor mixing ABC 0.2 0.4 0.4 0 70
    0.2 0.5 0.3 0 71
    0.2 0.6 0.2 0 72
    0.2 0.7 0.1 0 73
    0.3 0.1 0.6 0 74
    0.3 0.2 0.5 0 75
    0.3 0.3 0.4 0 76
    0.3 0.4 0.3 0 77
    0.3 0.5 0.2 0 78
    0.3 0.6 0.1 0 79
    0.4 0.1 0.5 0 80
    0.4 0.2 0.4 0 81
    0.4 0.3 0.3 0 82
    0.4 0.4 0.2 0 83
    0.4 0.5 0.1 0 84
    0.5 0.1 0.4 0 85
    0.5 0.2 0.3 0 86
    0.5 0.3 0.2 0 87
    0.5 0.4 0.1 0 88
    0.6 0.1 0.3 0 89
    0.6 0.2 0.2 0 90
    0.6 0.3 0.1 0 91
    0.7 0.1 0.2 0 92
    0.7 0.2 0.1 0 93
    0.8 0.1 0.1 0 94
    0 0.1 0.1 0.8 95
    0 0.1 0.2 0.7 96
    0 0.1 0.3 0.6 97
    0 0.1 0.4 0.5 98
    0 0.1 0.5 0.4 99
    0 0.1 0.6 0.3 100
    BCD 0 0.1 0.7 0.2 101
    0 0.1 0.8 0.1 102
    0 0.2 0.1 0.7 103
    0 0.2 0.2 0.6 104
    0 0.2 0.3 0.5 105
    0 0.2 0.4 0.4 106
    0 0.2 0.5 0.3 107
    0 0.2 0.6 0.2 108
    0 0.2 0.7 0.1 109
    0 0.3 0.1 0.6 110
    0 0.3 0.2 0.5 111
    0 0.3 0.3 0.4 112
    0 0.3 0.4 0.3 113
    0 0.3 0.5 0.2 114
    0 0.3 0.6 0.1 115
    0 0.4 0.1 0.5 116
    0 0.4 0.2 0.4 117
    0 0.4 0.3 0.3 118
    0 0.4 0.4 0.2 119
    0 0.4 0.5 0.1 120
    0 0.5 0.1 0.4 121
    0 0.5 0.2 0.3 122
    0 0.5 0.3 0.2 123
    0 0.5 0.4 0.1 124
    0 0.6 0.1 0.3 125
    0 0.6 0.2 0.2 126
    0 0.6 0.3 0.1 127
    0 0.7 0.1 0.2 128
    0 0.7 0.2 0.1 129
    0 0.8 0.1 0.1 130
    CDA 0.8 0 0.1 0.1 131
    0.7 0 0.1 0.2 132
    0.6 0 0.1 0.3 133
    0.5 0 0.1 0.4 134
    0.4 0 0.1 0.5 135
    0.3 0 0.1 0.6 136
    0.2 0 0.1 0.7 137
    0.1 0 0.1 0.8 138
    0.7 0 0.2 0.1 139
    0.6 0 0.2 0.2 140
    0.5 0 0.2 0.3 141
    0.4 0 0.2 0.4 142
    0.3 0 0.2 0.5 143
    0.2 0 0.2 0.6 144
    0.1 0 0.2 0.7 145
    0.6 0 0.3 0.1 146
    0.5 0 0.3 0.2 157
    0.4 0 0.3 0.3 148
    0.3 0 0.3 0.4 149
    0.2 0 0.3 0.5 150
    0.1 0 0.3 0.6 151
    0.5 0 0.4 0.1 152
    0.4 0 0.4 0.2 153
    0.3 0 0.4 0.3 154
    0.2 0 0.4 0.4 155
    0.1 0 0.4 0.5 156
    0.4 0 0.5 0.1 157
    0.3 0 0.5 0.2 158
    0.2 0 0.5 0.3 159
    0.1 0 0.5 0.4 160
    0.3 0 0.6 0.1 161
    0.2 0 0.6 0.2 162
    0.1 0 0.6 0.3 163
    0.2 0 0.7 0.1 164
    0.1 0 0.7 0.2 165
    0.1 0 0.8 0.1 166
    0.1 0.1 0.1 0.7 167
    0.1 0.1 0.2 0.6 168
    0.1 0.1 0.3 0.5 169
    0.1 0.1 0.4 0.4 170
    0.1 0.1 0.5 0.3 171
    0.1 0.1 0.6 0.2 172
    0.1 0.1 0.7 0.1 173
    0.1 0.1 0.7 0.1 174
    0.1 0.2 0.6 0.1 175
    Four-color ABCD 0.1 0.3 0.5 0.1 176
    mixing 0.1 0.4 0.4 0.1 177
    0.1 0.5 0.3 0.1 178
    0.1 0.6 0.2 0.1 179
    0.1 0.7 0.1 0.1 180
    0.1 0.7 0.1 0.1 181
    0.1 0.6 0.1 0.2 182
    0.1 0.5 0.1 0.3 183
    0.1 0.4 0.1 0.4 184
    0.1 0.3 0.1 0.5 185
    0.1 0.2 0.1 0.6 186
    0.1 0.1 0.1 0.7 187
    0.2 0.1 0.1 0.6 188
    0.2 0.1 0.2 0.5 189
    0.2 0.1 0.3 0.4 190
    0.2 0.1 0.4 0.3 191
    0.2 0.1 0.5 0.2 192
    0.2 0.1 0.6 0.1 193
    0.2 0.1 0.6 0.1 194
    0.2 0.2 0.5 0.1 195
    0.2 0.3 0.4 0.1 196
    0.2 0.4 0.3 0.1 197
    0.2 0.5 0.2 0.1 198
    0.2 0.6 0.1 0.1 199
    0.2 0.6 0.1 0.1 200
    0.2 0.5 0.1 0.2 201
    0.2 0.4 0.1 0.3 202
    0.2 0.3 0.1 0.4 203
    0.2 0.2 0.1 0.5 204
    0.2 0.1 0.1 0.6 205
    0.3 0.1 0.1 0.5 206
    0.3 0.1 0.2 0.4 207
    0.3 0.1 0.3 0.3 208
    0.3 0.1 0.4 0.2 209
    0.3 0.1 0.5 0.1 210
    0.3 0. 1 0.5 0.1 211
    0.3 0.2 0.4 0.1 212
    0.3 0.3 0.3 0.1 213
    0.3 0.4 0.2 0.1 214
    0.3 0.5 0.1 0.1 215
    0.3 0.5 0.1 0.1 216
    0.3 0.4 0.1 0.2 217
    0.3 0.3 0.1 0.3 218
    0.3 0.2 0.1 0.4 219
    0.3 0.1 0.1 0.5 220
    0.4 0.1 0.1 0.4 221
    0.4 0.1 0.2 0.3 222
    0.4 0.1 0.3 0.2 223
    0.4 0.1 0.4 0.1 224
    0.4 0.1 0.4 0.1 225
    0.4 0.2 0.3 0.1 226
    0.4 0.3 0.2 0.1 227
    0.4 0.4 0.1 0.1 228
    0.4 0.4 0.1 0.1 229
    0.4 0.3 0.1 0.2 230
    0.4 0.2 0.1 0.3 231
    0.4 0.1 0.1 0.4 232
    0.5 0.1 0.1 0.3 233
    0.5 0.1 0.2 0.2 234
    0.5 0.1 0.3 0.1 235
    0.5 0.1 0.3 0.1 236
    0.5 0.2 0.2 0.1 237
    0.5 0.3 0.1 0.1 238
    0.5 0.3 0.1 0.1 239
    0.5 0.2 0.1 0.2 240
    0.5 0.1 0.1 0.3 241
    0.6 0.1 0.1 0.2 242
    0.6 0.1 0.2 0.1 243
    0.6 0.1 0.2 0.1 244
    0.6 0.2 0.1 0.1 245
    0.6 0.2 0.1 0.1 246
    0.6 0.1 0.1 0.2 247
    0.7 0.1 0.1 0.1 248
    Note: k1+k2+k3+k4= 100% can have numerous combinations. Based on the four primary colors (four kinds of color slivers) by coupling and drafting, color alternating, gradient color matching, twisting and mixture, numerous color schemes can be formed. In addition, it is possible to form a segment-color yarn having a variety of color distribution in the yarn.
  • (6) Random dynamic control method of the density and blending ratio of the rotor spun yarn
  • The dynamic change rate of density of the rotor spun yarn is shown as below: ε ρ = Δρ ρ = ρ 1 Δ V 01 + ρ 2 Δ V 02 + ρ 3 Δ V 03 + ρ 4 Δ V 04 V 5 ρ 1 V 01 + ρ 2 V 02 + ρ 3 V 03 + ρ 4 V 04 V 5 = ρ 1 Δ V 01 + ρ 2 Δ V 02 + ρ 3 Δ V 03 + ρ 4 Δ V 04 ρ 1 V 01 + ρ 2 V 02 + ρ 3 V 03 + ρ 4 V 04
    Figure imgb0028
    and: ρ 1 = ρ 2 = ρ 3 = ρ 4 = ρ 0
    Figure imgb0029
    V 01 + V 02 + V 03 + V 04 = V 0
    Figure imgb0030
  • Then, ε ρ = Δ V 01 + Δ V 02 + Δ V 03 + Δ V 04 V 0 = Δ V 0 V 0
    Figure imgb0031
  • From the absolute increment of the linear density and relative increment of the linear density, it can be found that, the linear density change of the yarn, which totally depends on the V01+ΔV01, V02+ΔV02, V03+ΔV03, V04+ΔV04, can have 9 different patterns. Therefore, there can be 9 kinds of yarn in different forms.
    • ① A yarn with variable linear density, wherein one component of the yarn has variable linear density and three components of the yarn have invariable linear densities. ρ ' = ρ+Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 04
      Figure imgb0032
      or ρ ' = ρ+Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 03
      Figure imgb0033
      or ρ ' = ρ+Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 02
      Figure imgb0034
      or ρ ' = ρ+Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 01
      Figure imgb0035
    • ② A yarn with variable linear density, wherein two components having variable linear densities and two components having invariable linear densities. ρ ' = ρ+Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 01 + Δ V 02
      Figure imgb0036
      or ρ ' = ρ+Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 01 + Δ V 03
      Figure imgb0037
      or ρ ' = ρ+Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 01 + Δ V 04
      Figure imgb0038
      or ρ ' = ρ+Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 02 + Δ V 03
      Figure imgb0039
      or ρ ' = ρ+Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 02 + Δ V 04
      Figure imgb0040
      or ρ ' = ρ+Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 03 + Δ V 04
      Figure imgb0041
    • ③ A yarn with variable linear density, wherein three components having variable linear densities and one component having invariable linear density. ρ ' = ρ+Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 01 + Δ V 02 + Δ V 03
      Figure imgb0042
      or ρ ' = ρ+Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 01 + Δ V 03 + Δ V 04
      Figure imgb0043
      or ρ ' = ρ+Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 01 + Δ V 02 + Δ V 04
      Figure imgb0044
    • ④ A yarn with variable linear density, wherein four components having variable linear densities. ρ ' = ρ+Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 01 + Δ V 02 + Δ V 03 + Δ V 04
      Figure imgb0045
    • ⑤ A yarn with variable linear density, wherein one component of the yarn is continuous and three components of the yarn are discontinuous. ρ ' = ρ + Δρ= ρ V 0 V 01 + Δ V 01 + V 02 + Δ V 02 + V 03 + Δ V 03 + V 04 + Δ V 04 0 t T 1
      Figure imgb0046
      ρ ' = ρ + Δρ = ρ V 0 V 02 + Δ V 02 T 1 t T 2
      Figure imgb0047
      ρ ' = ρ + Δρ= ρ V 0 V 01 + Δ V 01 + V 02 + Δ V 02 + V 03 + Δ V 03 + V 04 + Δ V 04 T 2 t T 3
      Figure imgb0048
      ρ ' = ρ + Δρ = ρ V 0 V 02 + Δ V 02 T 3 t T 4
      Figure imgb0049
    • ⑥ A yarn with variable linear density, wherein two components of the yarn are continuous and two components of the yarn are discontinuous. ρ ' = ρ + Δρ= ρ V 0 V 01 + Δ V 01 + V 02 + Δ V 02 + V 03 + Δ V 03 + V 04 + Δ V 04 0 t T 1
      Figure imgb0050
      ρ = ρ + Δρ= ρ V 0 V 02 + Δ V 02 + V 04 + Δ V 04 T 1 t T 2
      Figure imgb0051
      ρ = ρ + Δρ= ρ V 0 V 01 + Δ V 01 + V 02 + Δ V 02 + V 03 + Δ V 03 + V 04 + Δ V 04 T 2 t T 3
      Figure imgb0052
      ρ = ρ + Δρ= ρ V 0 V 02 + Δ V 02 + V 04 + Δ V 04 T 3 t T 4
      Figure imgb0053
    • ⑦ A yarn with variable linear density, wherein three component of the yarn are continuous and one component of the yarn is discontinuous. ρ = ρ + Δρ= ρ V 0 V 01 + Δ V 01 + V 02 + Δ V 02 + V 03 + Δ V 03 + V 04 + Δ V 04 0 t T 1
      Figure imgb0054
      ρ = ρ + Δρ= ρ V 0 V 02 + Δ V 02 + V 03 + Δ V 03 + V 04 + Δ V 04 T 1 t T 2
      Figure imgb0055
      ρ = ρ + Δρ= ρ V 0 V 01 + Δ V 01 + V 02 + Δ V 02 + V 03 + Δ V 03 + V 04 + Δ V 04 T 2 t T 3
      Figure imgb0056
      ρ = ρ + Δρ= ρ V 0 V 02 + Δ V 02 + V 03 + Δ V 03 + V 04 + Δ V 04 T 3 t T 4
      Figure imgb0057
    • ⑧ A yarn with variable linear density, wherein four components of the yarn are continuous and have variable linear densities. ρ = ρ + Δρ= ρ V 0 V 01 + Δ V 01 + V 02 + Δ V 02 + V 03 + Δ V 03 + V 04 + Δ V 04
      Figure imgb0058
    • ⑨ The method of dynamic feed speed control of spun yarn Because Δ V 0 = Δ V 01 + Δ V 02 + Δ V 03 V 04
      Figure imgb0059
      ΔV may come from ΔV01, or come from ΔV02, ΔV03, and ΔV04, which can be determined by the blending ratio. Then: Δ V 01 = K 1 V 0 + ΔV V 01
      Figure imgb0060
      Δ V 02 = K 2 V 0 + ΔV V 02
      Figure imgb0061
      Δ V 03 = K 3 V 0 + ΔV V 03
      Figure imgb0062
      Δ V 04 = K 4 V 0 + ΔV V 04
      Figure imgb0063

Claims (12)

  1. A rotor spinning method for four-sliver asynchronous inputting and three-level carding, characterized in that:
    1) feeding fiber by combined feeding rollers with four rotational freedom degrees into carding area where a three-level carding roller is used for carding;
    2) moving the combined feeding rollers 1, 2, 3, 4 at linear speeds V01, V02, V03, V04, respectively; moving a rotor at a linear speed V4 and moving a guide roller at a linear speed V5; setting linear densities of four slivers drafted by four rollers to be ρ1, ρ2, ρ3, and ρ4, respectively, and setting a rotor spun yarn density to be ρ, such that a draft ratio of a rotor spinning yarn is as below: E = ρ 1 + ρ 2 + ρ 3 + ρ 4 V 5 ρ 1 V 01 + ρ 2 V 02 + ρ 3 V 03 + ρ 4 V 04 = ρ 1 + ρ 2 + ρ 3 + ρ 4 ρ
    Figure imgb0064
    a linear density of the rotor spun yarn is formed, ρ = ρ 1 V 01 + ρ 2 V 02 + ρ 3 V 03 + ρ 4 V 04 V 5
    Figure imgb0065
    wherein speeds of three carding rollers are as follows: a speed of a first carding roller is 1500-3000 rpm, a speed of a second carding roller is 3000-6000 rpm, a speed of a third carding roller is 6000-12000 rpm;
    3) blending ratios of four slivers in the rotor spinning yarn are K1, K2, K3, and K4, respectively: K 1 = ρ 1 V 01 ρ 1 V 01 + ρ 2 V 02 + ρ 3 V 03 + ρ 4 V 04
    Figure imgb0066
    K 2 = ρ 2 V 02 ρ 1 V 01 + ρ 2 V 02 + ρ 3 V 03 + ρ 4 V 04
    Figure imgb0067
    K 3 = ρ 3 V 03 ρ 1 V 01 + ρ 2 V 02 + ρ 3 V 03 + ρ 4 V 04
    Figure imgb0068
    K 4 = ρ 4 V 04 ρ 1 V 01 + ρ 2 V 02 + ρ 3 V 03 + ρ 4 V 04
    Figure imgb0069
    4) assuming that the speed V5 of the guide roller is invariable, the variables of feeding speeds V01, V02, V03, V04 of the feeding rollers of the four slivers are respectively as follows: V01' = V01 + ΔV01, V02' = V02 + ΔV02, V03' = V03 + ΔV03, V04' = V04 + ΔV04,, then the dynamic linear density of the rotor spun yarn is obtained according to formula (2) Δρ = ρ 1 Δ V 01 + ρ 2 Δ V 02 + ρ 3 Δ V 03 + ρ 4 Δ V 04 V 5
    Figure imgb0070
    5) assuming that ρ1 = ρ2 = ρ3 = ρ4 = ρ0, V01+V02+V03+V04 = V0, obtaining a reference blending ratio according to the formulas (3), (4), (5), (6) as K 1 = V 01 V 0 , K 2 = V 02 V 0 , K 3 = V 03 V 0 , K 4 = V 04 V 0 ,
    Figure imgb0071
    wherein when V01+V02+V03+V04→V01+ΔV01+V02+ΔV02+V03+ΔV03+V04+ΔV04, the blending ratio becomes as below: K 1 = V 01 + Δ V 01 V 0 + Δ V 0
    Figure imgb0072
    K 2 = V 02 + Δ V 02 V 0 + Δ V 0
    Figure imgb0073
    K 3 = V 03 + Δ V 03 V 0 + Δ V 0
    Figure imgb0074
    K 4 = V 04 + Δ V 04 V 0 + Δ V 0
    Figure imgb0075
    realizing dynamically adjustable spinning of different color blending ratios or color mixing ratios in the yarn with different fibers or colors by controlling V01, V02, V03, and V04.
  2. The method according to claim 1, characterized in that: assuming that ρ1 = ρ2 = ρ3 = ρ4 = ρ0, V01 + V02 + V03 + V04 = V0, obtaining a dynamic change rate of the rotor spun yarn density according to formulas (2) and (7): ε ρ = Δ V 01 + Δ V 02 + Δ V 03 + Δ V 04 V 0 = Δ V 0 V 0
    Figure imgb0076
    achieving a random dynamic regulation of the density and the blending ratio of the rotor spun yarn by controlling the speed of one of the four rollers.
  3. The method according to claim 2, characterized in that: ρ = ρ + Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 04
    Figure imgb0077
    or ρ = ρ + Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 03
    Figure imgb0078
    or ρ = ρ + Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 02
    Figure imgb0079
    or ρ = ρ + Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 01 ,
    Figure imgb0080
    changing speed of one of the rollers to achieve a yarn with variable linear density, wherein one component has variable linear density and three components have invariable linear densities.
  4. The method according to claim 2, characterized in that: ρ = ρ + Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 01 + Δ V 02
    Figure imgb0081
    or ρ = ρ + Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 01 + Δ V 03
    Figure imgb0082
    or ρ = ρ + Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 01 + Δ V 04
    Figure imgb0083
    or ρ = ρ + Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 02 + Δ V 03
    Figure imgb0084
    or ρ = ρ + Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 02 + Δ V 04
    Figure imgb0085
    or ρ = ρ + Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 03 + Δ V 04 ,
    Figure imgb0086
    changing speed of one of the rollers to achieve a yarn with variable linear density, wherein two components have variable linear densities and two components have invariable linear densities.
  5. The method according to claim 2, characterized in that: ρ = ρ + Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 01 + Δ V 02 + Δ V 03
    Figure imgb0087
    or ρ = ρ + Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 01 + Δ V 03 + Δ V 04
    Figure imgb0088
    or ρ = ρ + Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 01 + Δ V 02 + Δ V 04 ,
    Figure imgb0089
    changing speed of one of the rollers to achieve a yarn with variable linear density, wherein three components have variable linear densities and one component has invariable linear densities.
  6. The method according to claim 2, characterized in that: ρ = ρ + Δρ= ρ V 0 V 01 + V 02 + V 03 + V 04 + Δ V 01 + Δ V 02 + Δ V 03 + Δ V 04 ,
    Figure imgb0090
    changing speed of one of the rollers to achieve a yarn with variable linear density, wherein four components have variable linear densities.
  7. The method according to claim 2, characterized in that: ρ = ρ + Δρ= ρ V 0 V 01 + Δ V 01 + V 02 + Δ V 02 + V 03 + Δ V 03 + V 04 + Δ V 04 0 t T 1
    Figure imgb0091
    ρ = ρ + Δρ= ρ V 0 V 02 + Δ V 02 T 1 t T 2
    Figure imgb0092
    ρ = ρ + Δρ= ρ V 0 V 01 + Δ V 01 + V 02 + Δ V 02 + V 03 + Δ V 03 + V 04 + Δ V 04 T 2 t T 3
    Figure imgb0093
    ρ = ρ + Δρ= ρ V 0 V 02 + Δ V 02 T 3 t T 4 ,
    Figure imgb0094
    wherein speed change of four rollers and speed change of one roller alternate to realize a yarn with variable linear density wherein one component is continuous and three components are discontinus, wherein t, T1, T2, T3, and T4 represent time.
  8. The method according to claim 2, characterized in that: ρ = ρ + Δρ= ρ V 0 V 01 + Δ V 01 + V 02 + Δ V 02 + V 03 + Δ V 03 + V 04 + Δ V 04 0 t T 1
    Figure imgb0095
    ρ = ρ + Δρ= ρ V 0 V 02 + Δ V 02 + V 04 + Δ V 04 T 1 t T 2
    Figure imgb0096
    ρ = ρ + Δρ= ρ V 0 V 01 + Δ V 01 + V 02 + Δ V 02 + V 03 + Δ V 03 + V 04 + Δ V 04 T 2 t T 3
    Figure imgb0097
    ρ = ρ + Δρ= ρ V 0 V 02 + Δ V 02 + V 04 + Δ V 04 T 3 t T 4
    Figure imgb0098
    wherein speed change of four rollers and speed change of two rollers alternate to realize a yarn with variable linear density wherein two components are continuous and two components are discontinus, wherein t, T1, T2, T3, and T4 represent time.
  9. The method according to claim 2, characterized in that: ρ = ρ + Δρ= ρ V 0 V 01 + Δ V 01 + V 02 + Δ V 02 + V 03 + Δ V 03 + V 04 + Δ V 04 0 t T 1
    Figure imgb0099
    ρ = ρ + Δρ= ρ V 0 V 02 + Δ V 02 + V 03 + Δ V 03 + V 04 + Δ V 04 T 1 t T 2
    Figure imgb0100
    ρ = ρ + Δρ= ρ V 0 * V 01 + Δ V 02 + V 02 + Δ V 02 + V 03 + Δ V 03 + V 04 + Δ V 04 T 2 t T 3
    Figure imgb0101
    ρ = ρ + Δρ= ρ V 0 * V 02 + Δ V 02 + V 03 + Δ V 03 + V 04 + Δ V 04 T 3 t T 4
    Figure imgb0102
    wherein speed change of four rollers and speed change of three rollers alternate to realize a yarn with variable linear density wherein three components are continuous and one component is discontinus, wherein t, T1, T2, T3 and T4 represent time.
  10. The method according to claim 2, characterized in that: in control method of dynamic feeding speed of the yarn, ΔV0 = ΔV01 + ΔV02 + ΔV03 + ΔV04, change of the speed is derived from ΔV01, ΔV02, ΔV03, or ΔV04 and determined by the blending ratio, and then ΔV01 = K'1(V0+ΔV)-V01, ΔV02 = K'2(V0+ΔV)-V02, ΔV03 = K'3(V0+ΔV)-V03, ΔV04 = K'4(V0+ΔV)-V04.
  11. A device for realizing the method according to any one of the preceding claims, characterized in that, the device comprises a spinning system and a computer control system, the spinning system comprises a feeding and carding mechanism, a collecting and twisting mechanism, and a winding mechanism, characterized in that, the feeding and carding mechanism comprises combined feeding rollers having four rotational freedom degrees, a three-level carding roller; wherein a speed ratio of four rollers of the combined feeding rollers with four rotational freedom degrees can be adjusted, the collecting and twisting mechanism includes a fiber transport channel, a rotor, and a guide device; the winding mechanism includes a guide and winding mechanism; the computer control system includes a PLC programmable controller, a servo driver, a servo motor; wherein the combined feeding rollers with four rotational freedom degrees and the three-level carding roller are driven by the servo motor.
  12. The device according to claim 10, characterized in that the combined feeding rollers having four rotational freedom degrees comprises a shaft, a bearing, a hollow shaft, a first gear, a second gear, a third gear, a fourth gear, a washer, a first movable roller, a second movable roller, a third movable roller, and a fourth movable roller, wherein the first gear, the second gear, the third gear, and the fourth gear, the first movable roller, the second movable roller, the third movable roller, and the fourth movable roller rotate around the same axis, the first gear, the second gear, the third gear, and the fourth gear drive the first movable roller, the second movable roller, the third movable roller, and the fourth movable roller, respectively.
EP15901885.2A 2015-08-21 2015-10-30 Rotor spinning method and device for four-sliver asynchronous inputting and three-level carding Not-in-force EP3327184B1 (en)

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CN105040194B (en) 2018-01-16

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