Doffing cylinder

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Breaker card showing the doffing cylinder with its longer fancy card and the doffing knife below, at Masson Mill in Derbyshire, England Masson Mills WTM 19 Breaker Cards 5943.JPG
Breaker card showing the doffing cylinder with its longer fancy card and the doffing knife below, at Masson Mill in Derbyshire, England

A doffing cylinder, also called doffing roller or commonly just doffer is a component used in textile mills to remove fiber from the main cylinder of a card, on which the fibers have been straightened and aligned. The main cylinder of the card will have one or two doffers that comb and remove the fiber. [1] The doffer is set with pins that hold the fiber, which is then removed by a comb or knife and fed into the next stage of production. Doffers are also used in cotton pickers and other machinery that handle fiber.

Carding process that disentangles, cleans and intermixes fibres

Carding is a mechanical process that disentangles, cleans and intermixes fibres to produce a continuous web or sliver suitable for subsequent processing. This is achieved by passing the fibers between differentially moving surfaces covered with card clothing. It breaks up locks and unorganised clumps of fibre and then aligns the individual fibers to be parallel with each other. In preparing wool fibre for spinning, carding is the step that comes after teasing.

Cotton picker cotton pickers automate harvesting to maximize efficiency

The cotton picker is a machine that automates cotton harvesting in a way that reduces harvest time and maximizes efficiency.

Contents

Confusingly, the word doffer (meaning something that takes off, as in "doff your hat") is also used for mill workers whose job it is to remove full bobbins or pirns holding spun fiber and replace them with empty bobbins or pirns. In modern mills, a machine called a doffer may do this task.

Doffer

A doffer is someone who removes ("doffs") bobbins, pirns or spindles holding spun fiber such as cotton or wool from a spinning frame and replaces them with empty ones. Historically, spinners, doffers, and sweepers each had separate tasks that were required in the manufacture of spun textiles. From the early days of the industrial revolution, this work, which requires speed and dexterity rather than strength, was often done by children. After World War I, the practice of employing children declined, ending in the United States in 1933. In modern textile mills, doffing machines have now replaced humans.

Bobbin A spool or cylinder around which thread or yarn is coiled.

A bobbin is a spindle or cylinder, with or without flanges, on which wire, yarn, thread or film is wound. Bobbins are typically found in sewing machines, cameras, and within electronic equipment. In non-electrical applications the bobbin is used for tidy storage without tangles.

Pirn

A pirn is a rod onto which weft thread is wound for use in weaving. Unlike a bobbin, it is fixed in place, and the thread is delivered off the end of the pirn rather than from the centre. A typical pirn is made of wood or plastic and is slightly tapered for most of its length, flaring out more sharply at the base, which fits over a pin in the shuttle. Pirns are wound from the base forward in order to ensure snag-free delivery of the thread, unlike bobbins, which are wound evenly from end to end.

Early years

Some people have given credit to Richard Arkwright for inventing the doffer, which was incorporated in his machine, but others consider that it was invented by James Hargreaves. The design was refined by Samuel Crompton shortly after 1785. Before the surface of the carding cylinder reaches the doffer it passes a "fancy roller", which brushes and raises the fibers on the cylinder so they can be transferred to the doffer more easily. In a wool mill a doffer would move relatively slowly compared to the surface of the carding cylinder, picking up the fiber. The fiber would then be removed from the doffer by a comb. [2]

Richard Arkwright textile entrepreneur; developer of the cotton mill

Sir Richard Arkwright was an English inventor and a leading entrepreneur during the early Industrial Revolution. Although his patents were eventually overturned, he is credited with inventing the spinning frame, which following the transition to water power was renamed the water frame. He also patented a rotary carding engine that transformed raw cotton into cotton lap.

James Hargreaves was a weaver, carpenter and inventor in Lancashire, England. He was one of three inventors responsible for mechanising spinning. Hargreaves is credited with inventing the spinning jenny in 1764, Richard Arkwright patented the water frame in 1769, and Samuel Crompton combined the two creating the spinning mule in 1779.

Samuel Crompton Inventor, pioneer of the spinning industry

Samuel Crompton was an English inventor and pioneer of the spinning industry. Building on the work of James Hargreaves and Richard Arkwright he invented the spinning mule, a machine that revolutionised the industry worldwide.

Design improvements

Diagram showing name, location, and rotation of rollers used on a cottage carder Pat Green Jumbo Exotic Carder Schematic.jpg
Diagram showing name, location, and rotation of rollers used on a cottage carder

At first, the card clothing for wool mills was made in the form of sheets, and when attached to the cylinder and to all the rollers including the last doffer there were gaps of about an inch between the sheets. This made it impossible to make endless slubbings. Even when it became possible to wrap the doffer with fillet clothing with no gaps, sheets with gaps continued to be used because a continuous woolen sliver was too difficult to manage through the subsequent steps. [3]

A breakthrough was made with the ring doffer, where the surface was covered by alternating continuous rings of clothing about an inch wide, separated by spacing rings of some material like leather. The idea seems to have originated with Louis Martin in Europe in 1803, and may have been used by Arnold Pawtucket in 1812 in Rhode Island. Ezekial Hale of Haverhill, Massachusetts patented the idea in 1825. With this design, it became possible to produce continuous lengths of slubbing to feed into the next stage. [4]

Rhode Island State of the United States of America

Rhode Island, officially the State of Rhode Island and Providence Plantations, is a state in the New England region of the United States. It is the smallest state in area, the seventh least populous, and the second most densely populated, but it has the longest official name of any state. Rhode Island is bordered by Connecticut to the west, Massachusetts to the north and east, and the Atlantic Ocean to the south via Rhode Island Sound and Block Island Sound. It also shares a small maritime border with New York. Providence is the state capital and most populous city in Rhode Island.

Haverhill, Massachusetts City in Massachusetts, United States

Haverhill is a historic city in Essex County, Massachusetts, United States. Haverhill is located 35 miles north of Boston on the New Hampshire border and about 17 miles from the Atlantic Ocean. The population was 60,879 at the 2010 census.

Various inventors proposed improvements. Thus, in October 1835 Stephen R. Parkhurst filed a patent for a doffer made of a set of parallel wheels with rims about four inches wide, separated by an inch or slightly more. By setting the wheels at a slight angle, the whole surface of the main cylinder would be cleared by them. This doffer would feed a system of rollers that could feed the fiber onto spools or into machines that would immediately twist it into a thread. [5] However, the ring doffer was relatively inefficient. [6]

Modern doffers

The most common arrangement today uses a tape doffer completely wrapped in fillet clothing, producing a web the width of the card, which is then split into strips using an array of endless tapes. These tapes used to be made of leather, but today are usually of synthetic material. [6]

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Spinning mule machine used to spin cotton and other fibres

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Rolling (metalworking) metalworking process

In metalworking, rolling is a metal forming process in which metal stock is passed through one or more pairs of rolls to reduce the thickness and to make the thickness uniform. The concept is similar to the rolling of dough. Rolling is classified according to the temperature of the metal rolled. If the temperature of the metal is above its recrystallization temperature, then the process is known as hot rolling. If the temperature of the metal is below its recrystallization temperature, the process is known as cold rolling. In terms of usage, hot rolling processes more tonnage than any other manufacturing process, and cold rolling processes the most tonnage out of all cold working processes. Roll stands holding pairs of rolls are grouped together into rolling mills that can quickly process metal, typically steel, into products such as structural steel, bar stock, and rails. Most steel mills have rolling mill divisions that convert the semi-finished casting products into finished products.

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Heckling (flax) combing process used to clean and straighten scutched flax or other bast fibers

Heckling is the last of three steps in dressing flax, or preparing the fibers to be spun. It splits and straightens the flax fibers, as well as removes the fibrous core and impurities. Flax is pulled through heckling combs, which parts the locked fibers and makes them straight, clean, and ready to spin. After heckling flax is ready to be woven into linen.

Doubling is a textile industry term synonymous with combining. It can be used for various processes during spinning. During the carding stage, several sources of roving are doubled together and drawn, to remove variations in thickness. After spinning, yarn is doubled for many reasons. Yarn may be doubled to produce warp for weaving, to make cotton for lace, crochet and knitting. It is used for embroidery threads and sewing threads, for example: sewing thread is usually 6-cable thread. Two threads of spun 60s cotton are twisted together, and three of these double threads are twisted into a cable, of what is now 5s yarn. This is mercerised, gassed and wound onto a bobbin.

Yarn engineering is the process of constructing yarn using procedures designed to change its properties. The purpose of yarn engineering is to optimize the performance and minimize the cost of textile products through the process of selecting the most effective raw materials, fiber type, manufacturing method, and yarn structure[1].

References

Citations
  1. Doff and Doffer.
  2. Jenkins 1972, p. 79.
  3. Jenkins 1972, pp. 79-80.
  4. Jenkins 1972, pp. 80.
  5. Parkhurst 1836, p. 81.
  6. 1 2 Jenkins 1972, pp. 82.
Sources