ROTOR SPINNING

Rotor Spinning is a more recent method of yarn formation compared to Ring Spinning. This is a form of open-end spinning where twist is introduced into the yarn without the need for package rotation. Allowing for higher twisting speeds with a relatively low power cost. In rotor spinning a continuous supply of fibres is delivered from delivery rollers off a drafting system or from an opening unit.

The rotor spinning machine is unlike any other machine in the short staple spinning mill in the range of tasks it has to perform, namely all the basic operations:

Sliver feed: A card or drawframe sliver is fed through a sliver guide via a feed roller and feed table to a rapidly rotatingopening roller. Sliver opening: The rotating teeth of the opening roller comb out the individual fibers from the sliver clamped between feed table and feed roller.

After leaving the rotating opening roller, the fibers are fed to the fiber channel. Fiber transport to the rotor: Centrifugal forces and a vacuum in the rotor housing cause the fibers to disengage at a certain point from the opening roller and to move via the fiber channel to the inside wall of the rotor. Fiber collection in the rotor groove: The centrifugal forces in the rapidly rotating rotor cause the fibers to move from the conical rotor wall toward the rotor groove and be collected there to form a fiber ring. Yarn formation: When a spun yarn end emerges from the draw-off nozzle into the rotor groove, it receives twist from the rotation of the rotor outside the nozzle, which then continues in the yarn into the interior of the rotor. The yarn end rotates around its axis and continuously twists-in the fibers deposited in the rotor groove, assisted by the nozzle, which acts as a twist retaining element. Yarn take-off, winding: The yarn formed in the rotor is continuously taken off by the delivery shaft and the pressure roller through the nozzle and the draw-off tube and wound onto a cross-wound package. Between takeoff and package, several sensors control yarn movement as well as the quality of the yarn and initiate yarn clearing if any pre-selected values are exceeded.

Characteristics A good Open-end machine should have,

Higher productivity Higher Productivity:- This is a major criteria as productivity reduces the cost of manufacturing. The O.E machines which are now in market boasts of many a basic needs like, longer length of machine, higher speeds, able to process coarser hank, fewer changes for Count, easy access to parts (less downtime for cleaning), longer production time between cleaning schedules, computerized controls for less power consumption and lower downtime and complete report generation giving leads to problem area are some points to discuss.

High content sliver cans (up to 18)

Large Sliver Can:- In early days large machines were equipped with less distance between Rotors (Gauge of machine). This led to creeling of very small cans, which required frequent can changes. Each can change requires a break in the yarn. All major manufacturers currently allow cans up to 18 diameter leading to less breakage, less joining of yarn, hence better quality and higher productivity. Originally round cans were used. Rectangular cans are used because they double sliver capacity in the same sliver can footprint. Larger packages of yarn (4 to 5 kg) Large Final Package:- The final package size has continued to increase. The final package size is important because it reduces tube change frequency and thus reduces idle time for creeling. Current yarn packages typically weigh 4 to 5 kgs. The Savio Super Spinner 3000 currently has the largest package size at 6kgs.

Less power consumption Less Power Consumption:- Using individual motors and electronic controls for each of the various drives of the machine maximize energy efficiency and minimizes downtime.

Automation Automation:- All spinning machines, whether ring or open end, need yarn joining to repair breaks or start new sliver cans. Joining the yarn has historically been a labor intensive activity and a source of quality defects. Autopiecing units are robots that automate this process. Market leaders like Schlafhorst, Rieter, Savio have machines that incorporate good quality autopiecers and autodoffing. This automation leads to less material handling costs and helps improve quality of the final product.

Flexibility of spinning components Flexibility of spinning component:- Many vendors are offering machines that can be programmed to produce many different types of yarns. The ability to rapidly change production results in the flexibility to serve multiple markets. A contemporary spinning mill should be

able to produce a range of products: denim, knitting, towels, structured fabrics, construction fabrics and various other products like core spun, multi count etc. Handling count range. Handling count range:- Machines need to be easily programmed to spin yarns from 4sNe to 60sNe. This ability allows a single machine to produce yarns that cater to many different end user requirements.