Simplex Machine

Anusri Deb
Lecturer, (STEC)
Simplex machine
Objects or Functions of Speed Frame/ Simplex
machine

 Attenuation of drawn sliver to form roving of required count by drafting.

 Insert small amount of twist to give required strength to roving.
 Wind the twisted roving onto the bobbin.
 Build the roving in full length of bobbin in such a form which will faciliate handling,
transfer and feeding to ring frame.
Passage diagram of a Simplex machine
Description
1. The sliver obtained from the draw frame or after combing is used as feed material in
a simplex or roving machine.
2. This sliver is put into the large can.
3. This sliver, first of all, passes through separators.
4. From this point, the sliver goes over the guide roller and then tensioning rollers.
5. Now the slivers enter into the drafting zone, where it passes between drafting
rollers. Generally, a draft of 6–15 drafts is employed to the fed sliver. The drafting
system attenuates the sliver many times its original length and reduces the weight per
unit length of the sliver
6. The output material(roving) after drafting has very poor strength due to low linear
density, therefore it needs a little amount of twist to hold the fibers together. The
drafted strand of fibers passes through the flyer to provide this twist, Usually, 30-65
turns per meter are inserted into the roving.
7. There are spindles in the flyers on which the twisted roving gets wound.
Operations involved in Simplex Machine
 Creeling: Creeling is the feeding of sliver in simplex from cans through some guides
and separators. In modern simplex upto 132 drawn sliver can be creeled and in
conventional 40 drawn sliver creeled at a time .
 Drafting: Slivers draw frame are too coarse in hank to produce yarn. So an
intermediate attenuation of sliver from with a draft between 5-20 is carried out in this
machine. .
 Twisting: The delivered stand is too thin to hold it’s constituent fibers together. So, to
impart a slight strength the roving is given some twists. Usually 30- 35 turns are given
per meter which is created by roving flyer.
 Winding: Produced or twisted roving is wound on the bobbin by the winding process.
In winding the coils of sliver are arranged very closely to meach other so that as much
material can be wound on package as possible.
 Building: Build the roving on to bobbin such a form which will facilate unwinding,
handling and transfer to the next process.
 Doffing: Doffing is to replace an empty bobbin in place of a fully wound roving
bobbin. Doffing could be done manually or automatically.
Necessity of Speed Frame
 1. The first reason is related to the required draft. Sliver is a thick, untwisted strand that
tends to be hairy and to create fly. The draft needed to convert this to a yarn is in the region
of 300-500. The drafting arrangements of ring spinning machines, in their current forms, are
not capable of processing this strand in a single drafting operation to create a yarn of short-
staple fibers that meets all the normal demands on such yarns. The fine , twisted roving is
significantly better suited to this purpose.

 2. The second reason is that draw frame cans represent the worst conceivable mode of
transport and presentation of feed material to the ring spinning frame.
Drafting System of simplex

 Conventional
1. 4 over 4 (without apron)
2. 3 over 3 (without apron)

 Modern System
1. SKF PK 1500
2. SKF PK 1600
3. Pneumatic Drafting
4 over 4 ( conventional drafting system)

 When the center point & nip point of the rollers in drafting system remains in the same
vertical line then the drafting system is called conventional drafting system

Top Roller Condenser

Sliver
Roving

Front Zone Middle Zone Back Zone

Bottom roller
Roller Dia
Dia of front bottom roller 25.4mm
Dia of 2nd bottom roller 22.2mm
Dia of 3rd bottom roller 28.4mm
Dia of back bottom roller 28.4mm

Here top rollers are coated with synthetic rubber and bottom rollers are made of steel & spiral
flutted.

Roller Pressure system

Pressure system is dead weight & hook arrangement.

Advantages
[Link] roller causes less slippage and synthetic rubber prevent more fiber damage
[Link] drafting arrangement

Disadvantages
[Link] Gripping of fiber is poor.
[Link] fibers are not control properly
[Link] occurs
[Link] and thin places produce
[Link] roller distance should be changed fore even very small changed in fiber staple length
 4 over 4 Modern drafting system (SKF PK
1600)
 In modern drafting system the center point of top and bottom roller & their nip points
do not remain in the same vertical line.
Upper Apron
Condenser
Upper cradle

Roving Sliver

Lower Cradle Middle Zone Back Zone

Lower Apron
Front Zone
Features of 4 over 4 drafting system or SKF PK
1600
 It is a 4 over 4 drafting system.
 Draft range: Total draft 5-20
 Roller type:
• Top rollers are synthetic rubber-coated.
• Bottom rollers are made of steel.
 Roller weighting:
Spring loading or sometimes hook and deadweight arrangement.
 Roller hardness:
• The hardness of rollers is about 80 – 85 degree shore.
 Apron:
• The double apron is used
• Inside apron cradle is used.
• Apron thickness is 1 mm.
Advantages:
1. Regular and uniform drafting is possible.
2. Less irregularity.
3. The roller setting is flexible.
4. Better controlling and guiding of fibers occurs.
5. The capability of giving a high range of the draft.
6. Less tendency of roller lapping.

Disadvantage:
1. When the draft is below the lower limit then drafting is difficult to control.
2. Cracked open, badly joined leather apron produce bad roving and end breakage.
Difference between Conventional and
Modern Drafting System
Conventional Drafting system Modern Drafting System
 Here roller draft method is used.  Here apron draft method is used.
 Poor or no control of short fibres movement  Better control of short fibre movement
 Less influenced by changes in staple length and  More influenced by changes in staple length
length distribution. and length distribution.
 Irregular draft Distribution  Regular draft Distribution
 Draft range is about 6-10  Draft range is about 10-15
 Less spindle speed  Higher spindle speed
 Higher tendency to roller lapping & end  Lower tendency to roller lapping & end
breakage breakage
 Less production  Higher production
 Dead weight is used for roller weighting.  Pneumatic or spring loaded system is used for
roller weighting.
 Parts of Simplex m/c and their functions

[Link] rollers
Bottom rollers are made of steel and are mounted
in roller stands or the frame through the needle,
roller, or ball bearings. They are positively driven
from the main gear transmission or by a separate
drive. To improve their ability to carry the fibers
along, they are formed with flutes of one of the
following types :
1. axial flutes (a)
2. inclined flutes (spiral flutes) (b)
3. knurled fluting (c)

Knurled fluting is used on rollers receiving aprons,

to improve the transfer of drive to the aprons.
Spiral flutes give quieter running and more even
clamping of the fibers compared with axial fluting.
Rolling of the top rollers on spiral flutes takes
place in a more even manner and with less jerking.
The diameter of the bottom rollers can lie in the
range of 20 - 90 mm, but normally diameters
between 25 and 50 mm are used.
 2. Top roller

The top rollers are not positively driven. Ball

bearings are used almost exclusively in roller
mountings. The thick coating forming the roller
surface is made of synthetic rubber. An
important characteristic of this coating is its
hardness. Soft coats surround the fiber strand to
a greater extent than harder ones and thus guide
the fibers better. On the other hand, they wear
out more quickly. A soft coating is therefore
used where a good guide is necessary, i.e.
where few fibers have to be moved with high
draft levels (e.g. at the front rollers of the ring-
spinning machine). Where this is not required,
harder coatings are mostly used. Hardness is
specified in terms of degrees Shore. The
following ranges are defined:
• soft: 65° - 75° Shore
• medium: 75° - 80° Shore
• hard: above 80° Shore
Normally the diameters of top rollers are
between 25 and 40 mm.
[Link]
Condensers placed in the drafting zone help to prevent the fiber strand from spreading apart
during drafting.
Function of condenser:
1. It prevents the sliver not to feeding in the drafting zone without elongation.
2. Straighten the sliver.
3. Control the width.
4. Control roving strength.

[Link]
The upper aprons are short and made of synthetic rubber. The thickness of apron is about
1mm. Lower aprons are larger and made of same material as that of uppers. Aprons are used
to support the material which is being drafted and ultimately to reduce the variation in the
material i.e. material will be uneven. When a drafting force is applied, there is a chance of
variation. So to reduce this variation, aprons are provided. In the main drafting, zone aprons
are used for further control of the drawing sliver. In the zone, the number of fibers is less
and they are given draft so that any floating fiber content would occur fabric defects and it
has to be avoided.

.
[Link] Arm
Pressure is implemented on main drafting roller to improve the nip contact and higher
nip. Since a high drafting is taken place, the possibility to make slippages is somewhat
high. This is avoided and prevented to avoid long-term variations in subsequent
processes. The top rollers are well pressed on bottom rollers by applying pressure
through pressure arm.

6. Cradle
Cradle is a device that guides the top roller. It is usually made of plastic. Cradle length
varies with the length of staple fiber length.
Function of cradle:
• To reduce the loss of short fiber.
• Control the floating fiber to a possible extent.
• Help to impart a higher draft.
• Make the roller setting flexible.

[Link]:
The distance between top and bottom aprons is maintained by a small component called
“cradle spacer” or “spacer,” which is inserted between the nose bar of the bottom apron
and the cradle edge of top apron. The selection of spacer for a process depends on the
hank of the sliver, break draft, and roving hank
[Link]
A flyer is used to wind the roving on a bobbin and to impart twist into the roving revolving
around the bobbin at a speed 700-1800 rpm. Flyer inserts twist. Each flyer rotation creates one
turn in the roving.
Types of Flyer
[Link] mounted Flyer: It gets motion from the spindle. Design & drive easy.
2. Top mounted Flyer : It gets motion from the top of the [Link] most of the industries, top
mounted flyer is used since it allows automation of the doffing operation
[Link] Flyer(conventional): Reduce the spreading of the legs at high operating speed.

[Link]
A spindle is a long vertical cylindrical shaft on which the flyer is mounted at the top. The spindle
is mounted at its lower end in a bearing and the bobbin tube acts as neck bearing. Flyer through
spindle is driven by a set of gears housed in the spindle rail, which is stationary. Spindle speed
and flyer speed are same.

[Link] Rail
The bobbin rail is moving up and down continuously so that the coils must be wound closely and
parallel to one another to ensure that as much as a material is wound on the bobbin. Since the
diameter of the packages increases with each layer, the length of the roving per coil also will
increase. Therefore the speed of movement of bobbin rail must be reduced by a small amount
after each completed layer.
False Twister (Flyer Top)
False Twisters are used on the flyers to add a false twist when the roving is being twisted between the
front roller and the flyer. Because of this additional twist, the roving is strongly twisted and this
reduces the breakage rate. Secondly, the false twister serves as a guide to the roving as it enters the
hollow arm.
Because of the false twister, the roving becomes compact which helps to increase the length wound on
the bobbin. This compactness helps to increase the flyer speed also.
The false twist in roving without change in the real twist has following advantages:
[Link] roving is strongly twisted in the unsupported length leading to the flyer.
2. Roving Breakage rates in the spinning triangle are reduced .
[Link] fly generation.
[Link] roving hairiness.
5.A more compact roving formation.
[Link] capacity of bobbin is increased.
[Link] production rate for higher flyer speed.
[Link] unwinding behavior of roving at the ring frame.
Recent Development of Simplex Machine
1. Improved drafting system: By improved drafting system, 6 – 20 drafts can be imported
to a sliver.
2. Higher flyer speed: Modern flyers are capable of a speed of 1000 rpm whereas
conventional flyer rpm was 600. Thus production increased by 50%.
3. Plastic flyer: Lighter in weight and less power consumption.
4. Gearing in bath oil: This causes smooth running of m/c and less wear of m/c parts.
5. Auto stop motion: Different auto stop motions to reduce waste and increase efficiency.
a. Sliver stop motion
b. Roving stop motion.
c. Creel stop motion.
d. Doffing stop motion
6. Inching motion: This involves turning the flyer to the correct position for piecing when
m/c stops for any end breakage.
7. Monitoring system: Modern speed frame includes data monitoring system by direct
reading of—
a. Production
b. Efficiency
c. Speed of flyer
d. Stoppage time
e. Quality monitoring

8. Inverter motor:
a. Controls traversing motion
b. Controls tension on roving
c. Controls the fast wheel directly

9. Suction in the drafting zone

10. Improve roving quality
11. Can changing
12. Wide range of roving count (0.5 – 2.5 Ne )
WHAT IS BLOCK CREERLING?
 It means to keep the slivers of different cans in different length to avoid the problem of
ending all the slivers at the same time.
 Thus the worker can replace full cans in place of empty cans easily.

WHAT IS BREAK DRAFT?

The draft between back and middle roller is known as break [Link] is varied from (1.03-
1.50)
 Function
[Link] prepare the processed sliver for final drafting in the front zone.
[Link] to break the twist in the curled material to prepare it foe the final drafting.
[Link] to acquire higher draft between middle and front roller
Roving Winding Principle of Simplex
Machine
 There are two winding principle
1. Bobbin leading principle
2. Flyer leading principle
Bobbin leading principle
The surface speed of the bobbin is kept constant by gradually reducing the speed of the
bobbin while keeping the speed of the spindle or flyer constant. The process or principle of
roving winding is called bobbin leading.
Here, as the diameter of the bobbin increases, the speed of the bobbin is reduced, and the
two parts, the bobbin, and the flyer rotate very fast during the machine to wrap the roving
in the delivery part of the roving frame so that the roving slowly wraps around the bobbin.
 The bobbin speed is higher than flyer speed at all points of winding.
 The winding speed is constant throughout the process.
 With the increase of bobbin dia, the bobbin speed must be decreased.
 The variation o bobbin speed with the increase of bobbin dia must be constant.
 Less tension on roving or yarn
 Used in cotton spinning.
Bobbin leading principle (Mathematical relation
between bobbin dia and speed)
Let,
Front roller delivery = L inch/min
Spindle speed/flyer speed instant point of winding = Ns rpm
Bobbin speed at any instant point of winding = Nb rpm
Bobbin circumference = π d
So, Winding on speed ,Nw =(Nb-Ns) rpm
Again, Winding speed Nw = [ Speed = Delivery Length / Circumference)
πd
Therefore, we can write ,
=( Nb – Ns)
πd
Or, L= π d ( Nb – Ns)
So, with the passage of winding d will increase and L , π & Ns will be constant. So, Nb must be
decrease to keep L constant.
i.e. D ∝
That is to say , with the increase of bobbin dia , bobbin speed will gradually decrease in bobbing
leading principle.
Flyer leading principle
Flyer leading is the process of winding the roving bobbin through a spindle or flyer while
keeping the speed of the bobbin constant. But the condition here is that as the roving is
added to the bobbin, the diameter of the bobbin increases, thus the surface area of the
bobbin also increases. Therefore, to keep the winding fixed, as the diameter of the bobbin
increases, the speed of the spindle or flyer is gradually increased to keep the amount of
winding constant
 The flyer speed is higher than the bobbin speed at all points of winding.
 The winding speed is constant throughout the process.
 With the increase of bobbin dia, the bobbin speed must be increased.
 The variation o bobbin speed with the increase of bobbin dia must be constant.
 Higher tension on the roving yarn.
 Used in jute production.
Flyer Leading Principle (Mathematical relation
between bobbin dia and speed)
Let,
Front roller delivery = L inch/min
Spindle speed/flyer speed instant point of winding = Ns rpm
Bobbin speed at any instant point of winding = Nb rpm
Bobbin circumference = π d
So, Winding speed ,Nw =(Ns-Nb) rpm
Again, Winding speed Nw = [ Speed = Delivery Length / Circumference)
πd
Therefore, we can write ,
=( Ns – Nb)
πd
Or, L= π d ( Ns – Nb)
So, with the passage of winding d will increase and L , π & Nb will be constant. So, Ns must be
decrease to keep L constant.
i.e. D ∝
That is to say , with the increase of bobbin dia , flyer speed will gradually decrease in flyer
leading principle.
Factors considered for selection of twist in
roving:
 [Link] length of fibre
If staple length of fiber is more than less amount of twist will be required for expected
strength of roving.
 2. Fiber fineness
If the fiber is fine than more no. of fibers will be in yarn cross section. So, inter fiber
friction increases and less amount of twist will be enough for intended roving strength.
 [Link] Count
If roving hank increases more twist are required sufficient strength.
 [Link] of fiber
For strong man made fiber less twist is required and for natural fiber more twist is required