A high efficiency spinning method

Abstract

The application discloses a high-efficiency spinning method, which comprises the following steps: first step, cotton assorting; second step, opening and cleaning cotton; third step, carding; fourth step, drawing; fifth step, roving; and sixth step, spinning. The cotton lap prepared by the opened and cleaned cotton is fed into a carding and combing integrated machine by adopting a lap former, direct preparation of the cotton lap into a carded sliver is realized, integrated production of carding and combing is realized, and spinning efficiency is greatly improved. The prepared carded sliver is sequentially subjected to three drawing, roving and spinning to prepare cotton combing yarn, and an ultra-large draft spinning machine with a four-roller three-zone draft structure is adopted in the spinning process, so that the production of high-count yarn under the feeding of heavy-weight roving is realized, and the spinning efficiency is greatly improved.

Description

Technical Field

[0001] This invention relates to the field of new textile technologies, and in particular to a high-efficiency spinning method. Background Technology

[0002] The spinning process is the final step in yarn production. It involves drafting and twisting the roving several times over to produce fine yarn with a specific count that meets relevant quality standards. The quality of the fine yarn ultimately determines the quality of the finished product. Simultaneously, the spinning process is one of the most crucial steps in a cotton textile mill. The size of a textile mill's production scale is expressed by the total number of spinning spindles. The output per spinning spindle reflects the production level of the textile enterprise. Indicators such as fine yarn quality, raw material and power consumption, and labor productivity reflect the technological and management level of the textile enterprise. The amount of energy consumed in the spinning process determines the cost of spinning, and the breakage rate per thousand spindles is a key performance indicator for enterprises.

[0003] Currently, China's textile industry is undergoing a critical period of transformation from labor-intensive to technology-intensive, and intelligent and continuous textile production has become a hallmark and inevitable trend of modern textile factories. Among these trends, to reduce the impact of contact, friction, and collisions on yarn during the transportation of semi-finished products between processing steps, thereby reducing labor and improving work efficiency, continuous production lines are becoming the future development trend. Summary of the Invention

[0004] The purpose of this invention is to provide an efficient spinning method to achieve the production of high-count yarn under heavy-weight roving feeding, thereby significantly improving spinning efficiency.

[0005] This invention provides an efficient spinning method, comprising the following steps:

[0006] Step 1: Cotton blending: 100% Xinjiang long-staple cotton fiber is used;

[0007] Step 2: Opening and cleaning cotton: The selected cotton fibers are sequentially processed through cotton grabbing, cotton mixing, foreign fiber removal, vibration feeding, and single-handed rolling to obtain a relatively uniform cotton roll.

[0008] Step 3: Combing: The cotton lap obtained in step 2 is processed into combed cotton sliver by a combing and carding machine. In the combing and carding machine, the cotton lap is fed in a series of steps: the feeding section is gradually pressed and held; the licker-in section is held and opened and combed; the cylinder combing section is freely transferred and combed; the doffer stripping section is formed into a web and cut; the cotton layer gathering section is stacked and laid flat and transferred; the pressing and rolling section is guided and pressed into a roll; the nipper feeding section is periodically held and fed; the front end of the cylinder combing section is combed and straightened; the rear end of the separation and bonding section is combed and straightened and combined and guided out; and the sliver coiling section is guided and gathered into a sliver and continuously coiled in the sliver can.

[0009] Step 4: Drawing: The combed cotton sliver obtained in step 3 is processed into a finished cotton sliver through three drawing processes;

[0010] Step 5: Roving: The cotton sliver obtained in step 4 is stretched, thinned, twisted and wound into roving to produce cotton roving with a certain strength;

[0011] Step 6: Spinning: The 1-2 cotton rovings obtained in step 5 are fed together and then drawn, twisted and wound to produce cotton yarn with a certain strength. The spinning machine is an ultra-large drafting CNC spinning machine equipped with a compact spinning device and a drafting system with a four-roller three-zone drafting structure.

[0012] In the efficient spinning method described above, preferably, the cotton feeding section includes a carding feed roller and a feed plate. The feed plate is located at the lower part of the outer circumference of the carding feed roller, and a certain distance is maintained between the two. The distance between the feed plate and the carding feed roller gradually decreases from the cotton layer inlet to the outlet, thereby achieving gradual compression and gripping of the fed cotton lap under the rotation of the carding feed roller.

[0013] In the efficient spinning method described above, preferably, the licker-in opening portion includes a licker-in roller, on which carding cloth is distributed. The licker-in roller and the carding feed roller rotate in the same direction but at different speeds, with the licker-in roller rotating at a higher speed than the carding feed roller. During rotation, the carding cloth on the surface of the licker-in roller grips the cotton fibers output from the carding feed roller and the feed plate. This gripping process achieves the opening and combing action of one end of the cotton fiber under the grip of the carding feed roller and the feed plate. Simultaneously, as the carding feed roller and the licker-in roller rotate, the cotton fibers are continuously transferred onto the licker-in roller. A dust removal knife and a carding plate are provided at the bottom of the outer circumference of the licker-in roller. The cross-section of the dust removal knife is triangular, and the length direction of the dust removal knife is perpendicular to the... The length direction of the licker-in roller remains consistent. The carding plate has an arc-shaped structure, and its length direction is consistent with that of the licker-in roller. The cross-section of the carding plate is arc-shaped and parallel to the arc-shaped portion of the licker-in roller directly above it. Impurity drop slits are provided at equal arc intervals along the arc direction of the carding plate. Impurities in the cotton fibers are separated and removed by the separation of the airflow layer generated by the licker-in roller and the carding plate through the dust removal knife and the carding plate. Thus, a first impurity drop zone is formed between the distance between the carding plate and the licker-in roller and the distance between the dust removal knife and the licker-in roller; a second impurity drop zone is formed between the distance between the dust removal knife and the licker-in roller and the entrance of the carding plate; and a third impurity drop zone is formed between the entrance and the exit of the carding plate.

[0014] In the efficient spinning method described above, preferably, the carding section includes a carding cylinder with carding cloth distributed on its surface. The carding cylinder and the licker-in roller rotate at opposite speeds, with the carding cylinder rotating at a higher speed than the licker-in roller. During rotation, the carding cloth on the carding cylinder surface grips the cotton fibers carried by the needles on the licker-in roller surface, achieving a free-flowing carding effect on the cotton fibers. Simultaneously, as the licker-in roller and the carding cylinder rotate in opposite directions, the cotton fibers are continuously transferred onto the carding cylinder. A rotating cover plate is provided on the upper part of the outer circumference of the carding cylinder, with carding cloth distributed on the cover plate. The cover plate rotates in opposite directions to the carding cylinder. The cotton fibers gripped by the carding cylinder rotate with the carding cylinder. When they come into contact with the carding cloth on the cover plate, sliver decomposition occurs between the relatively moving carding cloths, thereby breaking down the bundled fibers into single fibers. A large perforated bottom is provided at the bottom of the carding cylinder.

[0015] In the efficient spinning method described above, preferably, the doffer stripping section includes a doffer that is close to and rotates in the opposite direction to the carding cylinder. The doffer rotates at a speed less than that of the carding cylinder. While the carding cylinder rotates and separates the cotton fibers, the doffer grabs a portion of the fibers from the carding cylinder's needle surface and agglomerates them into a fiber layer. During this process, fibers from a large area of ​​the carding cylinder are rapidly transferred and agglomerated onto a single unit area of ​​the slower-moving doffer. A cotton layer cutter is positioned above the doffer. The cotton layer cutter is driven by a motor to rise or fall via a pulley device. When the cotton fiber layer gathered by the doffer reaches a certain width, the cotton layer cutter is driven by the motor to fall and cut the cotton layer. After the cotton layer is cut, the cotton layer cutter is driven by the motor to rise and return to the initial position. The cotton fibers not grabbed by the doffer continue to be driven by the cylinder. When it rotates to below the carding cylinder, the cotton fibers, supported by the large sluice bottom, overcome their own gravity and centrifugal force and continue to rotate with the carding cylinder. At the same time, impurities with high centrifugal force fall and are removed along the impurity drop gaps of the large sluice bottom.

[0016] In the efficient spinning method described above, preferably, the cotton layer gathering section includes a cotton layer tray, which is a cuboid structure. A support rod is provided at the bottom of the cotton layer tray. The support rod is driven by a motor to move upward, downward, and slide left and right. A pressure sensor is provided on the cotton layer tray. In the initial state, the cotton layer tray is in a completely lowered and stationary state. At this time, the cotton layer cut by the cotton layer cutter slides directly into the cotton layer tray. The falling cotton layers are layered and stacked flat in the cotton layer tray. When the pressure sensor on the cotton layer tray detects that the pressure of the stacked cotton layers reaches a set value, the motor drives the support rod to first move upward and then slide left and right, thereby sending the cotton layer of the required thickness to the compaction and winding section.

[0017] In the efficient spinning method described above, preferably, the compaction and spooling section includes a compaction roller, a guide roller, and a spool roller. The cotton layer conveyed from the cotton layer tray in the cotton layer aggregation section is directly grasped and pressed by the compaction roller. Under the pressure of the compaction roller, the loose cotton layer before spooling is flattened and compacted to form a tight cotton spool. The formed cotton spool is guided by the guide roller and rotated by friction from a pair of cotton spool rollers and a pressing roller, thereby achieving uniform spooling and producing a cotton spool with uniform thickness and density.

[0018] In the efficient spinning method described above, preferably, the nipper feeding section includes a combing feed roller and a nipper plate, the nipper plate including an upper nipper plate and a lower nipper plate. A tension roller is provided at the rear of the nipper feeding section. The cotton roll output from the compression rolling section passes directly through the tension roller and is pressed by the combing feed roller. At this time, the tension of the cotton roll during feeding is adjusted by the tension roller, thereby achieving uniform and consistent entry of the cotton roll into the nipper feeding section under constant tension control. The cotton roll output by the combing feed roller is then held by the upper nipper plate and the lower nipper plate. The upper nipper plate and the lower nipper plate in the nipper feeding section periodically swing back and forth, and the periodic feeding of the cotton roll is achieved by the back and forth swing.

[0019] In the efficient spinning method described above, preferably, the carding section includes a combing cylinder and an upper top comb. The cotton lap fed by the periodically oscillating upper and lower nipper plates is effectively held by the nipper plates. The combing cylinder combs the front and middle parts of the cotton lap fiber bundles extending from the insert plate, thereby removing short fibers and some dust and impurities during the combing process and straightening and paralleling the fibers. The upper top comb combs the rear end of the fiber bundles, while preventing short fibers and dust and impurities trapped in the fibers from re-entering the cotton web.

[0020] In the efficient spinning method described above, preferably, the separating and combining part includes a set of separating roller pairs, each separating roller pair including an upper separating roller and a lower separating roller. In each working cycle, the cotton web from the previous working cycle is poured in first, and the front end of the fiber bundle fed by the nipper plate is grasped in time and superimposed on the poured cotton web to achieve combination. Because the speed of the separating nipper jaws is greater than the speed of the top comb feeding the fiber bundle, the fiber grasped by the separating nipper jaws is drawn out from the fed fiber bundle, and its tail end is combed by the top comb.

[0021] Compared with existing technologies, this invention feeds cotton laps obtained from opening and cleaning into a carding and combing integrated machine using a lap forming machine, thereby directly producing combed cotton slivers from the cotton laps. This achieves integrated production of carding and combing, significantly improving spinning efficiency. The resulting combed cotton slivers are then processed through three drawing, roving, and spinning processes to produce combed cotton yarn. Furthermore, the spinning process employs an ultra-large drafting spinning machine with a four-roller, three-zone drafting structure, enabling the production of high-count yarns with heavy-weight roving feeding, thus greatly improving spinning efficiency. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of the integrated carding and combing machine of the present invention.

[0023] Explanation of reference numerals in the attached diagram: 1 - Feed plate, 2 - Carding feed roller, 3 - Licking-in roller, 4 - Dust removal knife, 5 - Carding plate, 6 - Carding cylinder, 7 - Cover plate, 8 - Large bottom spool, 9 - Doffer, 10 - Cotton layer cutter, 11 - Pulley device, 12 - Cotton layer tray, 13 - Support rod, 14 - Press roller, 15 - Guide roller, 16 - Cotton lap roller, 17 - Pressing roller, 18 - Tension roller, 19 - Combing feed roller, 20 - Upper nipper plate, 21 - Lower nipper plate, 22 - Upper top comb, 23 - Combing cylinder, 24 - Separating roller pair, 25 - Guide plate, 26 - Pressure roller, 27 - Trumpet mouth, 28 - Upper sliver disc, 29 - Lower sliver can, 30 - Base plate. Detailed Implementation

[0024] The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0025] This invention relates to a high-efficiency spinning method. A cotton lap, obtained from opening and cleaning, is fed into a carding and combing machine using a lap-forming machine. Along the movement direction of the cotton lap within the machine, the carding and combing machine, from back to front, includes a cotton feeding section, a licker-in section, a cylinder carding section, a doffer stripping section, a pressing and lap-forming device, a nipper feeding section, a cylinder carding section, a separating and combining section, and a sliver forming section. This allows for the direct production of combed cotton sliver from the cotton lap, achieving integrated carding and combing production and improving spinning efficiency. The resulting combed cotton sliver is then processed through three drawing, roving, and spinning stages to produce combed cotton yarn. Furthermore, the spinning process utilizes a super-large drafting spinning machine with a four-roller, three-zone drafting structure, enabling the production of high-count yarn with a heavy-weight roving feed, significantly improving spinning efficiency. The specific steps include:

[0026] Step 1: Cotton blending: 100% Xinjiang long-staple cotton fiber is used, with a main fiber length of 36.5mm, a quality length of 39.0mm, a micronaire value of 3.7, a fineness of 1.39dtex, a short fiber rate of 13.5%, and an impurity content of 1.5%.

[0027] Step 2: Opening and Cleaning: The selected cotton fibers are sequentially picked up by a disc-type cotton picker according to the required blending ratio. During the picking process, the cotton fibers undergo initial opening and mixing. A blending and opening machine further opens, mixes, and removes impurities from the picked cotton fibers. A carding and beating opening machine then performs further opening, further separating and removing impurities from the cotton fibers. A foreign fiber removal machine separates and removes other fibers from the opened cotton fibers. Finally, the fibers are vibrated... The moving cotton feeder achieves opening and uniform feeding under vibration, thereby conveying the cotton layer evenly to the lap forming machine. The single-beater lap forming machine produces a relatively uniform cotton lap. During the opening and cleaning process, the raw cotton is gradually opened, mixed, and uniformly processed through the action of each individual machine. Following the process principles of "multiple compartments for use, fine cotton handling, thorough mixing, gradual opening, early removal of broken pieces, combing instead of beating, and minimal fiber damage", the quality is improved, and the cotton lap unevenness rate is reduced to below 1.2% and the impurity content is reduced to below 0.9%.

[0028] Step 3: Combing: The cotton lap obtained in step 2 is processed into combed cotton sliver by a combing machine. Along the movement direction of the cotton lap in the combing machine, the combing machine includes, from back to front, a cotton feeding section, a licker-in section, a cylinder combing section, a doffer stripping section, a cotton layer gathering section, a compacting and lap forming section, a nipper feeding section, a cylinder carding section, a separating and combining section, and a sliver coiling section.

[0029] Reference Figure 1As shown, the cotton feeding section includes a carding feed roller 2 and a feed plate 1. The feed plate 1 is located at the lower part of the outer circumference of the carding feed roller 2 and a certain distance is maintained between the two. The distance between the feed plate 1 and the carding feed roller 2 gradually decreases from the cotton layer inlet to the outlet, so that the cotton roll is gradually pressed and gripped by the rotation of the carding feed roller 2.

[0030] The opening section of the licker-in roller 3 includes the licker-in roller 3, on which carding cloth is distributed. The licker-in roller 3 and the carding feed roller 2 rotate in the same direction but at different speeds, with the speed of the licker-in roller 3 being greater than that of the carding feed roller 2. During rotation, the carding cloth on the surface of the licker-in roller 3 grips the cotton fibers output from the carding feed roller 2 and the feed plate 1. During the gripping process, one end of the cotton fiber is opened and combed under the grip of the carding feed roller 2 and the feed plate 1. At the same time, as the carding feed roller 2 and the licker-in roller 3 rotate, the cotton fibers are continuously transferred onto the licker-in roller 3. A dust removal knife 4 and a carding plate 5 are provided at the bottom of the outer circumference of the licker-in roller 3. The cross-section of the dust removal knife 4 is triangular, and the length direction of the dust removal knife 4 is consistent with the length direction of the licker-in roller 3. The carding plate 5 has an arc-shaped structure. The length direction of the carding plate 5 is consistent with the length direction of the licker-in roller 3. The cross-section of the carding plate 5 is arc-shaped, and the cross-section of the carding plate 5 is parallel to the arc surface of the licker-in roller 3 directly above it. Along the arc direction of the carding plate 5, there are slits for removing impurities at equal arc intervals. The impurities in the cotton fibers are separated and removed by the airflow layer generated by the rotation of the cotton fibers driven by the dust removal knife 4 and the carding plate 5. Thus, a first impurity removal zone is formed between the distance between the cotton feed plate 1 and the licker-in roller 3 and the distance between the distance between the dust removal knife 4 and the licker-in roller 3, which mainly removes large impurities. A second impurity removal zone is formed between the distance between the dust removal knife 4 and the licker-in roller 3 and the inlet of the carding plate 5, which mainly removes a small amount of large impurities and most small impurities. A third impurity removal zone is formed between the inlet and outlet of the carding plate 5, which mainly removes short fibers and dust.

[0031] The carding section includes a carding cylinder 6, on which carding cloth is distributed. The carding cylinder 6 and the licker-in roller 3 rotate at opposite speeds, with the carding cylinder 6 rotating faster than the licker-in roller 3. During rotation, the carding cloth on the surface of the carding cylinder 6 grips the cotton fibers carried by the needles on the surface of the licker-in roller 3, achieving a free-flowing carding effect on the cotton fibers. Simultaneously, as the licker-in roller 3 and the carding cylinder 6 rotate in opposite directions, the cotton fibers are continuously transferred onto the cylinder. A rotating cover plate 7 is provided on the upper part of the outer circumference of the carding cylinder 6, on which carding cloth is distributed. The cover plate 7 rotates in opposite directions to the carding cylinder 6. The cotton fibers gripped by the carding cylinder 6 rotate with the carding cylinder 6. When they come into contact with the carding cloth on the cover plate 7, the decomposition of slivers occurs between the relatively moving carding cloths, thereby breaking down the bundled fibers into single fibers. A large vent 8 is provided at the bottom of the carding cylinder 6.

[0032] The doffer stripping section includes a doffer 9, which is in close proximity to and rotates in the opposite direction to the carding cylinder 6. The doffer 9 rotates at a slower speed than the carding cylinder 6. While the carding cylinder 6 rotates and separates the cotton fibers, the doffer 9 grabs some fibers from the needle surface of the carding cylinder 6 and agglomerates them into a fiber layer. During this process, fibers from a large area of ​​the rapidly rotating carding cylinder 6 are transferred and agglomerated onto a single unit area of ​​the slower-moving doffer 9. A cotton layer cutter 10 is positioned above the doffer 9, and the cotton layer cutter 10 is connected to a pulley device 1. 1. Driven by a motor, the cotton layer rises or falls. When the cotton fiber layer gathered by the doffer 9 reaches a certain width, the cotton layer cutter 10 is driven by the motor to fall and cut the cotton layer. After the cotton layer is cut, the cotton layer cutter 10 is driven by the motor to rise and return to the initial position. The cotton fibers not grabbed by the doffer 9 continue to be driven by the carding cylinder 6. When it rotates to below the carding cylinder 6, the cotton fibers overcome their own gravity and centrifugal force under the support of the large bottom 8 and continue to rotate with the cylinder. At the same time, impurities with high centrifugal force fall down and are removed along the impurity drop gap of the large bottom 8.

[0033] The cotton layer gathering section includes a cotton layer tray 12, which is a rectangular structure. A support rod 13 is provided at the bottom of the cotton layer tray 12. The support rod 13 is driven by a motor to move upward, downward and slide left and right. A pressure sensor is provided on the cotton layer tray 12. In the initial state, the cotton layer tray 12 is in a completely lowered and stationary state. At this time, the cotton layer cut by the cotton layer cutter 10 slides directly into the cotton layer tray 12. The falling cotton layers are layered and stacked flat in the cotton layer tray 12. When the pressure sensor on the cotton layer tray 12 detects that the pressure of the stacked cotton layers reaches the set value, the motor drives the support rod 13 to first move upward and then slide left and right, thereby sending the cotton layer of the required thickness to the compaction and rolling section.

[0034] The compression and rolling section includes a compression roller 14, a guide roller 15, and a roll roller 16. The cotton layer conveyed from the cotton layer tray 12 of the cotton layer gathering section is directly grasped and pressed by the compression roller 14. Under the pressure of the compression roller 14, the fluffy cotton layer before rolling is flattened and compacted to form a tight cotton roll. The formed cotton roll is guided by the guide roller 15 and rotated by a pair of roll rollers 16 and a pressing roller 17, thereby achieving uniform rolling and producing cotton rolls with uniform thickness and density.

[0035] The nipper feeding section includes a combing feed roller 19 and a nipper plate. The nipper plate includes an upper nipper plate 20 and a lower nipper plate 21. A tension roller 18 is provided at the rear of the nipper feeding section. The cotton roll output from the compression rolling section passes directly through the tension roller 18 and is pressed by the combing feed roller 19. At this time, the tension roller 18 is used to adjust the tension during cotton roll feeding, thereby achieving uniform and consistent entry of the cotton roll into the nipper feeding section under constant tension control. The cotton roll output by the combing feed roller 19 is then held by the upper and lower nipper plates 21. The upper nipper plate 20 and the lower nipper plate 21 in the nipper feeding section swing back and forth periodically, thereby achieving periodic feeding of the cotton roll through the back and forth swing.

[0036] The combing section includes a combing cylinder 23 and an upper top comb 22. The cotton lap fed in by the periodic oscillation of the upper nipper plate 20 and the lower nipper plate 21 is effectively held by the nipper plate. The combing cylinder 23 combs the front and middle parts of the cotton lap fiber bundles that extend out of the insert plate, thereby removing short fibers and some dust and impurities during the combing process and straightening and paralleling the fibers. The upper top comb 22 combs the rear end of the fiber bundles, while preventing short fibers and dust and impurities trapped in the fiber bundles from re-entering the cotton web.

[0037] The separating and combining section includes a set of separating roller pairs 24. Each separating roller pair 24 includes an upper separating roller and a lower separating roller. In each working cycle, the cotton web from the previous working cycle is poured in first, and the front end of the fiber bundle fed by the nipper plate is grasped in time and superimposed on the poured cotton web to achieve combination. Because the speed of the separating nipper jaws is greater than the speed of the top comb feeding the fiber bundle, the fiber held by the separating nipper jaws is drawn out from the fed fiber bundle, and its tail end is combed by the top comb.

[0038] The sliver forming and coiling section includes pressure rollers 26 and a coiler. A trumpet 27 is provided at the upper part between the pressure rollers 26. The trumpet 27 extends between the pressure rollers 26. The cotton web output from the separation and bonding section is guided by the cotton guide plate 25 and enters the trumpet 27. It is gathered by the trumpet 27, thereby changing the cotton web from a mesh structure to a strip structure. During the gathering process, the cotton web has a longitudinal mixing effect due to the different arrival times at the trumpet 27, and is re-combined into strip-shaped cotton fibers. Then, it is pressed and fixed by the pressure rollers 26 and continuously wound into the cotton sliver can by the coiler to obtain combed cotton sliver. The coiler includes an upper coiling disc 28 and a lower sliver can 29. The lower sliver can 29 is embedded in a base plate 30. The upper coiling disc 28 and the base plate 30 are driven by corresponding transmission mechanisms to rotate in the same direction but at different speeds. The rotation speed of the upper coiling disc 28 is greater than that of the base plate 30. The combed cotton sliver is continuously coiled in the lower sliver can 29 after passing through the upper coiling disc 28.

[0039] Step 4: Drawing: The combed sliver obtained in Step 3 is processed into a finished sliver through three drawing processes. This improves the uniformity of the various cotton fibers within the combed sliver, improves the sliver structure, ensures parallel and straight fiber alignment, achieves a more complete separation state, and controls the short-segment unevenness, weight unevenness, and weight deviation of the sliver at a good level. The first, second, and final drawing processes all use 6 fibers combined, employing a forward drafting process, meaning the drafting ratio of the first drawing is less than that of the second drawing, and the drafting ratio of the second drawing is less than that of the first drawing. The draft ratio of the first draw is less than or equal to the number of draws, while the total draft ratio of the second and final draws is greater than or equal to the number of draws. This ensures better fiber separation and straightness, reduces fiber tangling and thick spots, and improves yarn quality. The basis weights of the three draws are 16.44 g / 5m, 16.39 g / 5m, and 16.2 g / 5m, respectively. The pressure of the rollers is 118×294×314×294, and the output speed of the compression roller 14 is 256.8 r / min.

[0040] Step 5: Roving: The cotton sliver obtained in Step 4 is drawn thinner and twisted into roving to produce cotton roving with a certain strength. The roving drafting further improves the straightness of the cotton fibers, and the twisting creates conditions for the high drafting of the spinning frame. The roving process design aims to improve the quality of the roving, achieving stable elongation, small weight difference, uniform yarn, compact structure, and good forming. The roving process should improve the mechanical finishing quality, ensure normal meshing of the drafting gears, and meet the specifications for roller bending and rubber roller eccentricity, without any lack of oil. The cotton collector openings should be consistent and the installation position appropriate. The rubber rollers should rotate flexibly, and the starting position of the rollers should be accurate to ensure stable elongation, keep the spindle shell clean, operate normally, and prevent cotton from getting caught in the channel. This improves the roving evenness, reduces weight unevenness, and reduces yarn defects. The roving weight is set to 10g / 10m.

[0041] Step 6: Spinning: The 1-2 cotton rovings obtained in Step 5 are fed together and then drafted, twisted, and wound to produce cotton yarn with a certain strength. The spinning machine is an ultra-large drafting CNC spinning machine equipped with a Toyota-type compact spinning device. The drafting system adopts a four-roller, three-zone drafting structure. Along the direction of fiber movement, the four rollers from back to front include the back roller, middle-back roller, middle-front roller, and front roller. The drafting system uses a Schüsen-type leaf spring cradle for pressure. The area between the back roller and the middle-back roller is the back drafting zone, with a drafting ratio set between 1.05 and 1.3. The back drafting zone plays a drafting and finishing role on the cotton roving fed into the drafting system, thereby significantly improving the straightness of the fibers in the cotton roving and making the force distribution between fibers more uniform. The area between the middle-back roller and the middle-front roller is the middle drafting zone. The drafting ratio of the middle drafting zone is set between 1.3 and 2.0. The middle drafting zone plays a transitional drafting and finishing role on the cotton sliver output from the rear drafting zone of the drafting system. Under the transitional drafting and finishing role of the middle drafting zone, the cotton sliver output from the rear drafting zone is initially drafted and thinned. At the same time, the interaction force between fibers is weakened and the uniformity is increased. The area between the middle front roller and the front roller is the front drafting zone. The drafting ratio of the front drafting zone is set between 30 and 100. The front drafting zone plays a main drafting role on the cotton sliver output from the middle drafting zone of the drafting system. Under the main drafting and finishing role of the front drafting zone, the cotton sliver output from the middle drafting zone is significantly drafted and thinned. At the same time, the interaction force between fibers is significantly weakened, thereby obtaining the required amount of cotton sliver. The cotton sliver output from the drafting system is then twisted into yarn and continuously wound onto the yarn bobbin.

[0042] Using Xinjiang long-staple cotton fiber as raw material, pure cotton combed yarn with a linear density of 5.8 tex was prepared by both the method of this invention and the traditional combed yarn production method. The corresponding process parameters are as follows:

[0043] (1) Process flow:

[0044] This invention comprises: FA003 type disc cotton picker—SFA035E blending and opening machine—FA106E type carding and beater cotton opener—YQ600H foreign fiber removal machine—SF161A vibrating feeder—A076F single beater lap forming machine—carding and combing integrated machine—FA306A type drawing frame—FA306A type drawing frame—FA306A type drawing frame—JWF1415 type roving frame—TH558 type CNC spinning frame

[0045] Traditional Process: FA003 Disc Cotton Picker — SFA035E Mixing and Opening Machine — FA106E Carding and Beating Opening Machine — YQ600H Foreign Fiber Remover — SF161A Vibrating Feeder — A076F Single Beating Lap Former — FA231C Carding Machine — FA306A Drawing Frame — JSFA360 Sliver Lap Former — E65 Combing Machine — FA306A Drawing Frame — FA306A Drawing Frame — FA306A Drawing Frame — JWF1415 Roving Frame — TH558 CNC Spinning Frame Key Process Parameter Design:

[0046] Opening and cleaning cotton:

[0047] FA003 type disc cotton grabber

[0048]

[0049] SFA035E Mixing Cotton Machine

[0050]

[0051] FA106E type carding beater cotton opener

[0052]

[0053]

[0054] A076F Single-hand Rolling Machine

[0055]

[0056] Traditional cotton combing process:

[0057] FA231C carding machine

[0058]

[0059] Traditional combing process preparation:

[0060] FA306A Drawing Mill Process Design Table (Pre-drawing)

[0061]

[0062] JSFA360 strip winding machine

[0063]

[0064]

[0065] Traditional combing process:

[0066] E65 Combing Machine

[0067]

[0068] This invention is a carding and combing machine:

[0069]

[0070] Parallelism:

[0071]

[0072]

[0073] Coarse yarn:

[0074]

[0075] Fine yarn:

[0076]

[0077] (2) Yarn quality

[0078]

[0079] The yarn quality test results of 5.8 tex pure cotton combed yarn for weaving produced using the method of this invention and the traditional combed yarn production method are shown in the table above. It is evident that, compared to the traditional process, the overall quality of the pure cotton combed yarn produced using the method of this invention is comparable, especially showing a slight advantage in yarn evenness and strength. This is solely due to the integrated carding and combing process employed in this invention, which reduces fiber damage compared to the traditional process. Furthermore, this invention achieves integrated carding and combing, eliminating the traditional combing preparation process, thus significantly improving spinning efficiency.

[0080] The above description, based on the embodiments shown in the figures, details the structure, features, and effects of the present invention. The above description is only a preferred embodiment of the present invention, but the present invention is not limited to the scope of implementation shown in the figures. Any changes made in accordance with the concept of the present invention, or equivalent embodiments modified to have equivalent changes, that do not exceed the spirit covered by the specification and figures, should be within the protection scope of the present invention.

Claims

1. A high-efficiency spinning method, characterized in that, Includes the following steps: Step 1: Cotton blending: 100% Xinjiang long-staple cotton fiber is used; Step 2: Opening and cleaning cotton: The selected cotton fibers are sequentially processed through cotton grabbing, cotton mixing, foreign fiber removal, vibration feeding, and single-handed rolling to obtain a relatively uniform cotton roll. Step 3: Combing: The cotton lap obtained in step 2 is processed into combed cotton sliver by a combing and carding machine. In the combing and carding machine, the cotton lap is fed in a series of steps: the feeding section is gradually pressed and held; the licker-in section is held and opened and combed; the cylinder combing section is freely transferred and combed; the doffer stripping section is formed into a web and cut; the cotton layer gathering section is stacked and laid flat and transferred; the pressing and rolling section is guided and pressed into a roll; the nipper feeding section is periodically held and fed; the front end of the cylinder combing section is combed and straightened; the rear end of the separation and bonding section is combed and straightened and combined and guided out; and the sliver coiling section is guided and gathered into a sliver and continuously coiled in the sliver can. During the doffer stripping process, a cotton layer cutter is installed on the upper part of the doffer. The cotton layer cutter is driven by a motor to rise or fall through a pulley device. When the cotton fiber layer condensed by the doffer reaches a certain width, the cotton layer cutter is driven by the motor to fall and cut the cotton layer. After the cotton layer is cut, the cotton layer cutter is driven by the motor to rise and return to the initial position. During the stacking and transfer of cotton layers: the cotton layers cut by the cotton layer cutter slide directly into the cotton layer tray. The falling cotton layers are stacked and laid flat in the cotton layer tray. When the pressure sensor on the cotton layer tray detects that the pressure of the stacked cotton layers reaches the set value, the motor drives the support rod to first move upward, and then slide left and right to send the cotton layer of the required thickness to the tightly rolled section. In the pressing and rolling section: the cotton layer conveyed from the cotton layer tray of the cotton layer gathering section is directly held and pressed by the pressing roller. Under the pressing of the pressing roller, the fluffy cotton layer before rolling is flattened and compacted to form a tight cotton roll. The formed cotton roll is guided by the cotton guide roller and rotated by a pair of cotton roll rollers and a pressing roller, so as to achieve uniform rolling and produce cotton rolls with uniform thickness and density. Step 4: Drawing: The combed cotton sliver obtained in step 3 is processed into a finished cotton sliver through three drawing processes; Step 5: Roving: The cotton sliver obtained in step 4 is stretched, thinned, twisted and wound into roving to produce cotton roving with a certain strength and a basis weight of 10g / 10m. Step 6: Fine yarn: After feeding the 1-2 cotton rovings obtained in step 5 together, the fine yarn is drawn, twisted and wound to produce cotton fine yarn with a certain strength. The fine yarn machine adopts an ultra-large drafting CNC fine yarn machine equipped with a compact spinning device, and adopts a drafting system with a four-roller three-zone drafting structure. The drafting ratio in the back drafting zone is set between 1.05 and 1.3 to draft and finish the fed cotton roving, thereby increasing the straightness of the fibers in the cotton roving and making the force distribution between the fibers more uniform. The draft ratio in the middle drafting zone is set between 1.3 and 2.0 to perform transition drafting on the cotton sliver output from the rear drafting zone, so that the cotton sliver is initially drafted and thinned, while the interaction force between fibers is weakened and the uniformity is increased. The draft ratio in the front drafting zone is set between 30 and 100. The cotton sliver output from the middle drafting zone is then subjected to main drafting, which significantly stretches and thins the cotton sliver. At the same time, the interaction force between the fibers is greatly reduced, resulting in the desired quantity of cotton sliver.

2. The efficient spinning method according to claim 1, characterized in that: The cotton feeding section includes a carding feed roller and a feed plate. The feed plate is located at the lower part of the outer circumference of the carding feed roller and a certain distance is maintained between them. The distance between the feed plate and the carding feed roller gradually decreases from the cotton layer inlet to the outlet, so that the cotton roll is gradually pressed and gripped and fed in under the rotation of the carding feed roller.

3. The efficient spinning method according to claim 2, characterized in that: The licker-in opening section includes a licker-in roller, on which carding cloth is distributed. The licker-in roller and the carding feed roller rotate in the same direction but at different speeds, with the licker-in roller rotating at a higher speed than the carding feed roller. During rotation, the carding cloth on the surface of the licker-in roller grips the cotton fibers output from the carding feed roller and the feed plate. This gripping process achieves the opening and combing effect of one end of the cotton fiber being held by the carding feed roller and the feed plate. Simultaneously, as the carding feed roller and the licker-in roller rotate, the cotton fibers are continuously transferred onto the licker-in roller. A dust removal knife and a carding plate are provided at the bottom of the outer circumference of the licker-in roller. The cross-section of the dust removal knife is triangular, and the length direction of the dust removal knife is aligned with the length direction of the licker-in roller. The carding plate has an arc-shaped structure, and its length direction is consistent with that of the licker-in roller. The cross-section of the carding plate is arc-shaped and parallel to the arc surface of the licker-in roller directly above it. Impurity removal slits are provided at equal arc intervals along the arc direction of the carding plate. Impurities in the cotton fibers are separated and removed by the dust removal knife and the carding plate sequentially dividing the airflow layer generated by the rotation of the cotton fibers driven by the licker-in roller. Thus, a first impurity removal zone is formed between the distance between the cotton feed plate and the licker-in roller and the distance between the dust removal knife and the licker-in roller, a second impurity removal zone is formed between the distance between the distance between the dust removal knife and the licker-in roller and the entrance of the carding plate, and a third impurity removal zone is formed between the entrance and the exit of the carding plate.

4. The efficient spinning method according to claim 3, characterized in that: The carding section includes a carding cylinder with carding cloth distributed on its surface. The carding cylinder and the licker-in roller rotate at opposite speeds, with the carding cylinder rotating faster than the licker-in roller. During rotation, the carding cloth on the carding cylinder surface grips the cotton fibers carried by the needles on the licker-in roller surface, achieving a free-flowing carding effect on the cotton fibers. Simultaneously, as the licker-in roller and the carding cylinder rotate in opposite directions, the cotton fibers are continuously transferred onto the carding cylinder. A rotating cover plate is provided on the upper part of the outer circumference of the carding cylinder, with carding cloth distributed on the cover plate. The cover plate rotates in opposite directions to the carding cylinder. The cotton fibers gripped by the carding cylinder rotate with the carding cylinder. When they come into contact with the carding cloth on the cover plate, slivers are broken down between the relatively moving carding cloths, thereby breaking down the bundled fibers into single fibers. A large perforated bottom is provided at the bottom of the carding cylinder.

5. The efficient spinning method according to claim 4, characterized in that: The doffer stripping section includes a doffer, which is close to the carding cylinder and rotates in the opposite direction to the carding cylinder. At the same time, the rotation speed of the doffer is less than that of the carding cylinder. While the carding cylinder rotates and combs the cotton fibers, the doffer grabs some fibers from the carding cylinder's needle surface and condenses them into a fiber layer. During this process, fibers from a large area of ​​the carding cylinder are rapidly transferred and condensed onto a unit area of ​​the slower-moving doffer. Cotton fibers not grabbed by the doffer continue to be driven by the carding cylinder. When the rotation reaches below the carding cylinder, the cotton fibers, supported by the large drain bottom, overcome their own gravity and centrifugal force and continue to rotate with the carding cylinder. Meanwhile, impurities with high centrifugal force fall and are removed along the impurity drop gaps of the large drain bottom.

6. The efficient spinning method according to claim 5, characterized in that: The cotton layer gathering part includes a cotton layer tray, which is a rectangular structure. A support rod is provided at the bottom of the cotton layer tray. The support rod is driven by a motor to move upward, downward and slide left and right. A pressure sensor is provided on the cotton layer tray.

7. The efficient spinning method according to claim 6, characterized in that: The compression and winding section includes compression rollers, guide rollers, and cotton roll rollers.

8. The efficient spinning method according to claim 7, characterized in that: The nipper feeding section includes a combing feed roller and a nipper plate. The nipper plate includes an upper nipper plate and a lower nipper plate. A tension roller is provided at the rear of the nipper feeding section. The cotton roll output from the compression rolling section passes directly through the tension roller and is pressed by the combing feed roller. At this time, the tension of the cotton roll during feeding is adjusted by the tension roller, thereby achieving uniform and consistent entry of the cotton roll into the nipper feeding section under constant tension control. The cotton roll output by the combing feed roller is then held by the upper nipper plate and the lower nipper plate. The upper nipper plate and the lower nipper plate in the nipper feeding section periodically swing back and forth, and the periodic feeding of the cotton roll is achieved by the back and forth swing.

9. The efficient spinning method according to claim 8, characterized in that: The combing section includes a combing cylinder and an upper top comb. The cotton lap fed in by the periodic oscillation of the upper and lower clamping plates is effectively held by the clamping plates. The combing cylinder combs the front and middle parts of the cotton lap fiber bundles extending out of the insert, thereby removing short fibers and some dust and impurities during the combing process and straightening and paralleling the fibers. The upper top comb combs the rear end of the fiber bundles, while preventing short fibers and dust and impurities trapped in the fibers from re-entering the cotton web.

10. The efficient spinning method according to claim 9, characterized in that: The separation and bonding section includes a set of separation roller pairs, each of which includes an upper separation roller and a lower separation roller. In each working cycle, the cotton web from the previous working cycle is poured in first, and the front end of the fiber bundle fed by the nipper plate is grasped in time and superimposed on the poured cotton web to achieve bonding. Because the speed of the separation nipper jaws is greater than the speed of the fiber bundle fed into the top comb, the fibers grasped by the separation nipper jaws are drawn out from the fed fiber bundle, and their tail ends are combed by the top comb.

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