Shanghai - Kaili Yarn Splicer: - Working Manual. - Spares Parts Catalogue.
Shanghai - Kaili Yarn Splicer: - Working Manual. - Spares Parts Catalogue.
YARN SPLICER
__Working Manual.
__Spares Parts Catalogue.
__ For AIR and AQUA models
Sales / Service and Spares by:
dnaexp_india@hotmail.com
dnaexpINDIA@gmail.com
0091-172-3042434 – TELEFAX
0091-98155 56146 _ MOBILE
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1.    PRODUCT APPLICATION
       Pneumatic Air Splicers Type QF7305/QF7306 are new-type accessories for yarn-
splicing used in winding process of textile industry, which can be instead of conventional
knotting ways ( such as Weaving Knot Splicer and Tight Knot Splicer) so as to get the
excellent knotless yarn and obvious benefits in economy and society for improving the
quality of yarn and cloth.
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           Applicable Range             Yarn       Spliced           Air
                                        Count      Strength          Pressure
                                                                     (MPa)
                                                                     Constant
                                                                     Pressure
QF7304     Applied to pure cotton 20S 80S          More than         0.6 0.62
           single yarn and some                    80% of raw
           cotton/synthetic       fiber            yarn
           single yarn (synthetic fiber
           content less than 10%)
QF7307     Applied to the spandex       10S 60S    more than         0.65 0.7
B          core-spun single yarn                   80% of raw
                                                   yarn
                                                                                     3
2.    The two ends of the yarn are individually secured by the clamper and the yarn
      clamp, and the scissors cut the surplus yarn. Then, the chamber cover will close on
      the mingling chamber .( See Fig. 2)
3.    When the air blast within the detwisted tube, the ends of the yarn blast into the
      detwisted oscillators after cutting the surplus yarn and the yarn is untwisted, being
      effected by the high-frequency oscillating slices.
4.    The opened ends are retracted from the detwisted oscillators and blended within
      the mingling chamber. ( See Fig. 4)
5.    A jet of compressed air is directed into the mingling chamber and the final joint is
      made.( See Fig. 5)
6.    The chamber cover will now open and the yarn is ready to be removed and would
      onto the bobbin. At this stage the unit is ready to start the next cycle.
Pneumatic Splicer Type QF7305/7306 consists of Cylinder Driving Part, Splicing Part
and Clamping & Yarn-cutting part which are relatively independent, easy to repairing
and assembling. Its constructional characteristics are:
2. The working time for the splicer can be adjusted within 0.3--1 second.
3.    In driving, the cylinder drives the piston rod (which does thread-clamping, thread-
      cutting & thread-plucking by means of the cam-gear) and the air distributing-rod
      (which connects the air circuits for twisting & detwisting at a proper time). The
      operation is simple and reliable.
4.    Adopted by means of high-frequency oscillation, the detwisting is quick and
      effective. This is a breakthrough in comparison with the conventional ways of
      Detwisting. The air volume for detwisting is adjustable and its effects can be
      checked.
5.    As to the yarns within the range of 30-& tex, they can be suitable with simple
      adjustments.
                                                                                         4
3.2 Design of air flow
    Air compressor decides the size of piping system and the size of the pipe decides the
air flow and pressure. Take 8 ~10 coners of Model 1332 as an example, the main pipe
should be the water pipe of 1 1/2″ 2″, the optimum is 2″. The main pipe is usually fixed
closely to the tailstock. 1 1/2″pipes is used as sub-pipe which extend to the middle
underneath of the coner. Taking 100 spindles as a standard, the 1 1/2″ pipes should
extend to the fifth leg counting from the tailstock, and further 10 cm 20 cm should be
cut and hinged to use. Such piping system is a perfect design and there is no more air
pressure drop.
                                                                                            5
6
               Splicing Part
Inlet Connection
                           7
IV. ADJUSTMENT FOR SPLICING PROCESS
        This splicer is suitable to different varieties of yarns the adjustments of Splicing
Time of Cycle (T), Splicing Length (L) and Ends Preparation Air Volume (E). Attention
should be paid that the structures of these three factors are independent, but have definite
relations to the features of splicing.
    The adjusting device is located at the bottom of the air splicer. The speed is divided
into 6 grades(T=1 6).The 6th grade is the slowest while the 1st is the fastest. It means
the speed is slowing down with the increase of the grade. But when all 1 6 grades can’t
meet the demand we can adjust the screw inside a small hole in the center of the device,
which is named main adjusting screw to provide wide speed ranges. The one outside is
called the micro-adjusting screw, which can be used only after finishing the main
adjustment. Normally it is prohibited to adjust. It will cause bad bounding effect if
adjusted too fast. Please take care of adjustment (Don’t adjust the rate of the AS too fast
to get high productivity blindly).
                                                                                          8
4.2    Length of the Splicing Area (L)
  This device is called yarn-dialing piece adjustment and used to adjust the congruent
length. It is located on the top of the air splicer with one at both sides of the hull. There
are also 6 grades (in practical operation, adjusting L=1 6 is only for reference). The
quality of the congruent length affects the fineness, appearance smooth property and
strength of the yarn. In order to meet the demand of strength, choosing shorter length will
gain better appearance. The ideal splicing fineness should be controlled within 1 1.1
times of the raw yarn. The congruent length will change together with the yarn counts,
and the length of splicing area (L) should be adjusted. To adjust the yarn-dialing piece,
we must adjust the pieces on both sides together and the positions of the two pieces
should be kept on a line after adjusting. Splicing area is directly correlated with the
fineness and smooth property of the yarn. So we should often check whether the position
is correct.
  This device is on the top of the air splicing device and at the back of hull. It’s specially
used to regulate the air jet volume of detwisting, which can also be divided into 6 grades
(the range would exceed the 6 levels in practical operation). The greater its value is, the
greater air jet volume that the oscillator of detwisting can give out. The function of
regulating E is to increase or reduce the jet volume of detwisting at the same time, thus to
reach the ideal detwisting effect. Generally speaking, air jet volume alters according to
yarn count changes. But the altering range is not so large, Those in the range of
20S(Ne) 40S(Ne) do not change basically, under 20S (Ne) adjust E to maximum, above
40S(Ne) adjust E to a bit less maximum. When E is adjusted to maximum, arrow of
indicator in the device should point downward, vertical with the ground, of which real
regulation range is between 1 and site of arrow pointing vertical ground. Exceed the
range can result less jet volume of de-twisting, even no jet volume.
    In practical operation, detwisting effect will directly impact the splicing feature. We
can not only utilize experience, but also use the detwisting effect to judge whether the
detwisting is normal or not. Different detwisting way can result in different splicing
situations as following.
                                                                                            9
       A. Ideal ends preparation                        Correct splice
  Oscillator should be adjusted mainly according to the twisting directions of yarn. The
adjustment of splicing cavity is more complicated because the appropriated types of
splicing cavity should be chosen according to kinds of yarn in some special cases.
 The operation of air splicer will affect the nodes quality directly. The tied yarn can’t
pass through the electronic yarn cleaner, so it requires concentration in the air splicer
operating. The following is operating experience achieved in the past few years only for
reference.
    Firstly, pick up the broken ends from bobbin with thumb and forefinger of right hand,
pass through the guide plate and drag board, and then put the yarn in diagonal state into
the air splicer. Secondly, pick up the broken ends from bobbin by left hand, and put ends
in diagonal state into the air splicer too. .Now through the splicing hole, we will see the
two yarns crossing together in the splicing hole, also the two yarns are in the opening of
oscillator. Two ends of yarn are amalgamated on left hand at this moment and drawn
straight. These two yarn are yarn tail also called waste yarn. And then hold that yarn in
the bobbin and draw straight with the thumb and forefinger after the right hand
unclamped. Push the handle of air splicer with the thumb of the right hand. After
movements of the air splicer are finished, right hand begins to carry the yarn. It should
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incline gently to the left so as to ensure that yarn is taken out smoothly (vertically
carrying will break yarn). While taking out yarn, look over the ranges of the splicing area,
check with eyes, ensure the tied yarn meet the quality requirement, then wind the yarn.
Two waste yarns produced on air splicer should have been on the left hand all the time.
Otherwise it will cause the waste yarn brought into bobbin.
1.      The yarn is put at the bottom of the guide thread kettle in diagonal state, two yarns
        are in crossing state in splicing cavity and open the operating air way.
2.      Both ends of yarn are hold by gripper and waste yarn is cut off, then splice cover
        closes.
3.      The detwisting tube begins jet to make the ends cut off after-yarn enter the
        detwisting oscillator and begin detwisting.
4.      The detwisting thread is conducted out of the oscillator and overlapped in the
        Splicer cavity.
5.      Splicer cavity both jet air and spray at the same time to intermingling two yarn
        heads.
6.      Craft movement reset, the twisted yarn is wound on the bobbin after opening cover
        of cavity.
5.2. Maintenance of air splicer
    When using air splicer of Model QF7304, Model QF7305, Model QF7304 and Model
QF7305, maintenance is very important. Whether maintenance is regular or not will
influence product quality directly. Some buyers seldom pay any attention to it, and think
that all kinds of yarn can be produced when having air splicer, and always owe all
problems to quality of air splicer. Wear and tear will normally happen in all products and
trouble frequency is related to wearing degree of the parts. It is made up of nearly 240
kinds of parts in total and most parts are unavoidably worn. We can guarantee the quality
and reduce the cost by trouble-shooting in sprout. So a full-time maintenance staff is
needed. Only in this way could the product quality and build their own brands. How to
make the maintaining better? The most important is that maintenance staff should have
extremely strong sense of responsibility. Secondly, maintenance staff should have certain
knowledge and technological accomplishment.
    How to maintain well? The preparative work before maintenance includes allocating
the air splicer directly to certain person. The spare machine should be ready all the time,
and the serial number should be registered on the notebooks so that the maintenance staff
could know every air splicer and avoid blind use. When using the spare machine to
replace the defected one ,it is better to make the record of every change every week in
order to assure the maintenance is purposeful. Replace the spare machine again after the
defected machine is repaired well and make it ready again. Working in this way for a
certain time one will realize that maintenance is in an order manner and can improve his
own of quick judging and solving the trouble. After accomplishing this, he can begin
daily maintenance work..
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Daily maintenance: First is to check whether the spare machine has been changed, then
clean every air splicer in production, refuel (using clean lubricant or spindle oil), and
carry on a basically overall inspection to every air splicer, pinpoint the problems and
solve it in time. Particularly pay close attention to the oscillator, oscillating slice, position
of blade and part of splice cavity, because those parts will directly influence quality of the
tied yarn. After checking, try to splice several heads (generally3 5). If the effect is good
enough, we can begin with the next one. If the trouble of an air splicer can’t be solved
within 10 minutes, it must be replaced by the spare one until after the defected one is
repaired. The maintenance work should be done every day to assure high productivity.
The air splicer of Model QF7304 and Model QF7305 must be cleaned, refueled and
maintained every day.
Monthly maintenance: After running for 300 000 400 000 times (about one month),
every air splicer should be given a detail maintenance. The maintenance includes:
disassemble the air splicer wash cylinder air pipes and driving parts once with
kerosene or oil. Kerosene is optimal owing to a little lubrication function, which can
avoid damaging cylinder. Then use a compressed air gun to blow away all the dirt aiming
pipes and rub up. Then check every part, such as: gasket, skeleton frame, blade, yarn-
dialing sheet and driving roller, change a new one if necessary. Among them gasket is
more easily torn, and should be changed frequently. The inter surface of cylinder should
be lubricated with thin grease (2 # lubrication grease or 7015/7016 aviation TM high and
low temperature lubrication grease) again when installed. During installing piston, more
lubrication grease should be spread at piston and around the gasket. Then put the rest
lubricating grease at the cylinder entrance into the cylinder after installing the piston.
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VI. TABLE OF WORN-OUT SPARE PARTS
                                                                                    13
 Unsmooth     1.Wrong operating methods         1.Lift the yarn up while yarn-
 yarn         2.The damped block is worn-out    flowing
 flowing      into slot or the yarn can’t be pressed
                                                2. Replace the damped block.
              by the fall plate.                (0210) Or the fall plate (0225)
 Unsteady     1.Unsteady pressure               1.Check the regulation of the
 strength     2.Loose yarn-plucking plate       pressure
 and          3. Faster speed                   2. Check the setting-up of the
 appearance                                     butterfly plate spring or replace it
                                                3. Adjust “T” to a high number
 The        1.Leakage of the seal-ring          1. Replace the seal-ring
 piston-rod 2. Unbalance of the four lock nuts 2. Adjust the nuts or the screws
 fails to   or the screws on the gantry housing
 return     3. Narrow gap between the cylinder
            and the piston                      3. Modify/replace the piston
   1. Rotate the 0424B, and push the handle. If there are drops spaying from the rotated
      little hole (0424B), the trouble is in the one-way value associative component on
      (0400-5B). If there are no drops spaying, check the one-way associative
      component under (0400-4B) and the water pipe of (0414B) to see whether it is
      blocked. If they are both in order, check the air value of (0400-2B) associative
      component to see whether it can move or the nut on it is off .If it is in order, use
      the air gun blowing the water course to remove the foreign matter blocked in it
   2. Trouble in one-way value: Two sides are smooth or two sides are obstructed.
      Dissemble the one-way value, wash it and reinstall; change the one-way value.
   3. The air value of (0400-2B) does not move. Deformation of the nylon part in the air
      piston results in the friction between nylon and air cylinder. Method of check:
      dissemble the (0114) gasket of the value. It is good if the value can move up and
      down freely in the air cylinder; if the gasket can not put into the cylinder or it is
      very tight, then the value has been deformed and needs repair or change.
                                                                                        14
Not          1. There is no water or mist in the 1. Fill the water tank with
enough          water tank.                         water or adjust the spraying
Strength     2. The type of the splicing cavity     quantity.
                and oscillator is incorrect.     2. Reselect the type and twist
                                                    direction.
Water        1. The seal of the water tank is 1. Change or remedy involved
tank         broken or ignored.                  gasket.
leakage
No mist 1. No water.                                 1.   Fill water.
sprayed 2. The water level is lower than the         2.   Fill water.
             standard line.                          3.   Repair or change.
          3. Single-way value is out of work.        4.   Dissemble parts in the
          4. Cotton yarn and sundries enter               water tank , clean out the
             and block the water tank, water              material with water gun and
             pipe and up-down single-way                  remove the matter out of the
             value.                                       one-way value and water
          5. Deformation of the air value                 inlet hole in the cylinder.
             prevents the movement or the            5.   Repair or change the air
             value nut is off.                            piston.
Unstable 1. The seal (0111 and 0114) of the          1.   change the gasket (0111
spraying,    cylinder is broken or wore out.              and 0114) and spray them
water for 2. Single-way value is out of work.             with grease.
adjusting 3. The seal of Ø4×1 and Ø3×0.8 is          2.   Repair or change the single-
bigger,      broken or aging.                             way value.
no water 4. The movement of air piston is            3.   Chang the worn-out seal.
for small    slow.                                   4.   Check the air course
                                                          whether smooth, spay the
                                                          piston cylinder and piston
                                                          with grease, then change the
                                                          seal (0114).
IX.    MOUNTING
      The correct mounting and operating of the Air Splicer consist of the mounting of
      air supply system, piping circuit and the auxiliaries of the winding frame. The
      details will be described as follows:
                                                                                            15
purified compressed-air, so there will be some definite requirement for the
pressure, the flow and the purity of the air-supply.
The working pressure of the Air Splicer is 0.54----0.68 Mpa. Normally, we may
consideration of the piping loss and safety operation regulations, the sufficient
pressure of the air supply should be assured.
Flow is another key parameter effecting on the splicing features. According to the
measurement, the maximum air consumption for one single air splicer is one liter
each time. By calculating the numbers of the air splicers, the later developing
margins and the air leakage, the quota air exhaustion for the air supply should be
sufficient. If the air exhaustion for the air supply is 400 liter/minute, it may be met
the needs of 25 air splicers running in the same time. Moreover, the diameters, of
the main and branch pipings should be rationally assured. The actual insufficient
flow may be caused by the smaller diameters. For example, while operating 8 sets
of air splicers, the diameter of the main piping can’t be less than 25 mm and that
of the branch piping can’t be less than 8 mm.
The purity of the air supply is an important problem, which can’t be neglected.
Other wise the oil (water), dirts and other impurities will be gathered within the
parts. This will influence the splicing quality and mechanical operation. If the high
temperature gas exhausted from the compressor transfer directly to the splicer, due
to the resucing of the temperature along the line. Therefore, the following system
may usually be adopted: (See Fig. 10 )
2.    The iron-sheet rail can be a suspensible style. This is convenient to do the cleaning
      work. It may also be mounted on the ground, but the size “H” can’t be so long as
      to influence the running of the caterpillar or the small cart. ( See Fig. 12 ) During
      mounting, the steadiness of the rail should be paid attention to and kept in straight
      line in between, The tops of the fixed screws should not be shown up the bottom
      of the solt, The iron-sheet slot with its holes in the inner-side ( or in the bottom )
      should be mounted in the centre for passing the air-transferring pipe.
3.    One end of the nylon caterpillar should be fixed in a position left ( right ) of the
      center so as to let the another end of its length just running to the two ends
      following after the small cart. Take the mounting of the air splicer on the 50-
                                                                                         17
18
     spindle ( single-sided ) Winder Model 1332 as an example; generall taking a
     position left ( right ) about 0.2 meter, the nylon caterpillar needs actually 152
     sections ( section gauge: 0.045 meter ). If mounting two air splicers on the 60-
     spindle ( single-sided ) winder, two ests of nylon caterpillars may be separately
     mounted on the two sided of the relative length a position left ( right ) 0.2 meter.
     It needs 95 x 2 = 190 sections ( The relative length of the air-transferring pipe may
     be calculated like this ) Besides, a declined transmitting board should be set-up to
     keep the nylon caterpillar reciprocating smoothly.
     The another end of the nylon caterpillar is fixed with the small cart by a pull-rod.
     (See Fig. 14) The structure showing in Fig. 14 is for reference only. The height of
     the pull-rod should be higher than the iron-sheet rail. In Fig. 14, the air-pipe is
     hoped tightly on the pull-rod. The nylon caterpillar is inserted tightly inside the
     slot.
4.   The air splicer is mounted on the support of the small cart by means of two
     mounting holes.(The poerating lever is leaning towards the side of the winder )
     and well adjusted its dip-angle up and down. Caution: the yarn-bag of the small
     cart should be laid on the right side so as to be easy for operating.
5.   After the air-transferring pressing tube is connected with the air circuit by means
     of the quick-repaceable connector, the air supply will be open. Then check the air
     leakage, the regular pressure and the smooth running of the small cart. Thus the
     trial running can be carried out.
X. ILLUSTRATIONS OF ACCESSORIES
1.   accessories list for the driving part of the cylinder ( Assembly parts )
2.   Accessories list for the splicing parts ( Assembly parts )
3.   Accessories list for the thread-clamping parts of the scissors
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1.     Accessories List for the Driving Part of the Cylinder ( Assembly Parts )
                                 Accessories List
                                 -------------------
0101         Valve Stem               0124              Torsion Spring Dowel
0102         O. Ring                  0125              Torsion Spring
0103         Cage                     0126              Cover Spacer
0104         RIng Guide               0127              Lever Spacer
0105         Bush                     0128              Connecting Pulley Shaft
0106         Valve Stem               0129              Connecting Dowel
0107         Gasket                   0130              Riveting Axle
0108         Cage                     0131              Connecting Pulley
0109         Index                    0132              Connecting Rod
0110         Pin                      0133              Cover Screw
0111         O. Ring                  0134              Slider
0112         Cylinder Stop-block      0135              Cylinder Bottom Stop-block
0113         Cylinder Body Base       0136              Linking Plate
0114         O. RIng                  0137              Connecting Torsion Spring
0115         Nozzle                   0138              Stop-block
0116         O. Ring                  0139              Hose Connecting Bush
0117         Piston Screw             0140              Inlet Nozzle Connector
0118         Piston Plate             0141              Pressing Lever
0119         Piston                   0142              Pin Tie-spacer
0120         Piston Shaft             0143              Lever Bush
0121         Cuylinder Body           0146              Leaning Bush
0122         Tie Rod Pin              0147              Washer
0123         Cover
                                   Assembly Parts
                                   ------------------
                                                                                       20
21
2.     Accessories List for the Splicing Parts ( Assembly Parts )
                                   Accessories List
                                   -------------------
                                   Assembly Parts
                                    -----------------
0200-1       Air-circuit Guide Head              0200-7     Left Damper
0200-2       Right Oscillator (Z)                0200-8     Right Damper
0200-3       Left Oscillator (S)                 0200-9     Bridge
0200-4       Left Oscillator (Z)                 0200-10    Chamber Cover
0200-5       Rigjht Oscillator (S)               0200-11    Mingling Chamber (S)
0200-6       Cover                               0200-12    Mingling Chamber (Z)
                                                                                   22
23
3. Accessories List for the Thread-clamping Parts of the Scissors (Assembly Parts)
                                  Accessories List
                                                                                      24
25
         Accessories List (Water Parts)
Assembly Parts
                                                           26
27