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(Woodhead Publishing India in Textiles) Bhattacharya, Someshwar S. - Shaikh, Tasnim N - Engineering Techniques of Ring Spinning-Woodhead Publishing India PVT LTD (2016) PDF
(Woodhead Publishing India in Textiles) Bhattacharya, Someshwar S. - Shaikh, Tasnim N - Engineering Techniques of Ring Spinning-Woodhead Publishing India PVT LTD (2016) PDF
(Woodhead Publishing India in Textiles) Bhattacharya, Someshwar S. - Shaikh, Tasnim N - Engineering Techniques of Ring Spinning-Woodhead Publishing India PVT LTD (2016) PDF
Engineering techniques of
ring spinning
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Contents
Preface ix
4. Twisting mechanism 49
4.1 Introduction 49
4.2 Twist mechanism in ring spinning 49
4.3 Working elements of twisting mechanism 50
4.4 Twist 88
4.5 References 95
vi Engineering techniques of ring spinning
5. Balloon theory 97
5.1 Introduction 97
5.2 Vibrating string theory in brief 97
5.3 Application of vibrating string theory to ring spinning 99
balloon
5.4 Basic conditions for stable spinning 101
5.5 Spinning parameters influencing spinning balloon height 101
5.6 References 103
8. Doffing 143
8.1 Introduction 143
8.2 Doffing 143
8.3 Types of doffing 144
8.4 Basic working elements of auto doffing 145
8.5 Doffing preparation 147
8.6 Doffing cycle 147
8.7 References 149
vii
Contents
Index 211
Preface
Abstract: Ring frame is the last machine in the production chain of fiber-to-yarn
conversion process. It is designed to convert roving to final state yarn by drafting
and twisting. The product yarn is wound in a peculiar pattern on a bobbin,
suitable for the forthcoming processes in the sequence. Ring frame holds a major
share in defining cost and quality of a spinning mill product. Thus spinning mill
economy and performance keys lies in the hands of ring frame. So, many a times
in narrower sense, ring spinning term is used only to the ring frame.
Key words: Ring frame, versatile, drafting, twisting, economy
1.1 Introduction
Spinning refers the conversion of staple fibers to continuous length twisted
strand of fibers that is yarn, of desired size. According to the structural
characteristics, yarn is the continuous strand of straight, parallel and randomly
arranged fibers twisted together. Thus conversion process of fibers to yarn
includes number of steps. The entire sequence of process is known as spinning.
Since ring and traveller are used as a media for inserting final turns of twist to
the strand, the set is recognized as ring spinning.
1.3 References
1. De Barr and Catling H. (1965). ‘Manual of Cotton Spinning: The Principles and
Theory of Ring Spinning,’ Manchester, The Textile Institute.
2. Gilbert R. Merrill (1959). ‘Cotton Ring Spinning’, Mass, Gilbert R. Merrill, Library
of Congress catalogue card number: 59-10906.
3. W. Klein (1987). ‘The Manual of Textile technology: Vol. I – The Technology of Short
Staple Spinning’, Manchester, The Textile Institute.
2
Basic features of ring spinning machine
2.1 Introduction
Ring spinning process is designed to convert continuous strand of group of
fibers known as roving to yarn. Roving holds the same technical definition
of ring spun yarn, but they differ in terms of their fineness (size) and amount
of twist employed. The roving stands on coarser side (0.6 s Ne to 2.5s Ne)
with quite a low amount of twist (0.7 to 1.2 TM). These values purely depend
upon the type of fibers in process and type of yarn to be spun. However, steps
follow during conversion mechanism remain same irrespective of variations
in feed material characteristics or yarn characteristics desire. Thus the basic
objectives and set up of ring frame remains identical for the very wide range
of yarns.
2.5 References
1. Gilbert R. Merrill (1959). ‘Cotton Ring Spinning’, Mass, Gilbert R. Merrill, Library
of Congress catalogue card number: 59-10906.
2. Rieter, Spun Yarn Systems, http://www.rieter.com/cz/rikipedia/articles/ring-spinning.
[Accessed 10 June 2014].
3
Design features of creel and drafting
system variables
Abstract: The entire ring spinning machine structure can be bifurcated into
three basic sections according to their role in production process. These divisions
are true for all categories, viz., (i) creel section, (ii) drafting section, (iii) spinning
section, and (iv) winding and bobbin building section. The contribution of each
section in the production course is well defined. The machine components are
accordingly engineered to meet these objectives. No doubt in order to maintain
pace with high speed production techniques, they have undergone many changes
in terms of their metallurgy, shape, dimension, etc. Since lot many areas and
their respective details are involved under these heading. So, the content is
divided into four chapters. The first part deals with creel section and drafting
section only. Their machine variables and respective changes in their engineering
design with advanced technology are briefly summarized in this chapter.
Key words: Creel, regular creel, skewer, open creel, pivot holder, sprung arms,
umbrella creel, drafting system, steel rollers, soft rollers, twine roller, loose boss
roller, roller bearing, staff length, fiber guidance devices, double apron, short
apron, long apron, roller nip, spacer, distance clip, scavenger roller, clearer roller,
pneumafil, bonda waste, soft waste, white waste, inverter, transducer, draft
constant, draft change wheel, high draft ratio, high draft speed, spinning triangle,
angle of wrap, roller stand angle
3.1 Introduction
Previous chapter has focused on the basic structure and aims of ring spinning.
Accordingly, the entire ring spinning is divided into three basic sections for all
categories: (i) creel section, (ii) drafting section, and (iii) spinning and winding
section. The contribution of each section in the production course is well
defined. The machine components are accordingly engineered to meet these
objectives. No doubt in order to maintain pace with high-speed production
techniques, they have undergone many changes in terms of their metallurgy,
shape, dimension, etc. They are briefly summarized in this chapter.
Regular creel
This creel is made up of three wooden boards, top creel board, middle creel
board and bottom creel board (Fig. 3.1). They form two compartments
to accommodate the required number of bobbins. Bobbins are mounted in
zigzag fashion in two raw per compartment to get enough spacing for ease of
donning and retaining alignment with the feed line. The boards are supported
on cross beams, capable of making vertical adjustments on vertical support
bars provided at regular interval. The number of cross beams varies depending
on the length of production end. The support bars are fitted on roller beams.
The distance between the creel boards is adjusted to suit the size of supply
package. Hence all the packages are mounted on wooden spindle known as
skewer. So, setting of the boards is done in such a way that the skewer projects
Design features of creel and drafting system variables 11
well into the holes in the upper one but does not project above its upper
surface. Holes have been punched in zigzag pattern as per spindle gauge and
covered well with porcelain guides on creel boards. Porcelain guides reduces
friction between skewer and board hole. Top and bottom boards have such an
arrangement only on one working side, but the middle one provided on both
the sides. Skewers fit into these guides, to work with negligible abrasion.
Skewer: It is a long hard wood spindle, tapered at both the ends (Fig. 3.2).
Its working cylindrical height is known as barrel. The barrel diameter of the
skewer (dB) is always smaller than the inner diameter of the supply bobbin
(dP), to avoid undue friction between them, at the point of roving withdrawal.
The barrel is rounded at bottom to form the base, to support the bobbin base
and not allow it to slide down further.
The roving bobbin is rotated by the pull of the roving. Owing to bigger
inner diameter of the bobbin, it rotates freely around the skewer, without
making any frictional contact. Strands of roving are drawn from the bobbin
to the roving guide of the drafting system. The difference in the path length
for top and bottom compartments of the creel adds to the unwinding tension
variations. Thereby smooth steel guide rod is provided, outside and well
above middle guide board. All the rovings from the upper compartment are
12 Engineering techniques of ring spinning
lead over this rod before entering to the roving guides. This can minimize the
tension variations due to difference in their path lengths.
Open creel
This creel uses bobbin overhead suspension pivots instead of bobbin holders;
skewer, so often referred as overhead creel. They are bolted onto several
support rails (triangular channel) arranged one behind the other along the
entire length of the machine (Fig. 3.3). There is one pivot for each spindle.
Hence quite smaller in size and suspended overhead onto support rail, offers
much higher free open space. Thereby put under the name of open creel. This
abundant open space provides enough room for the creeling and air circulation
in the cleaning process.
external force. When the sprung arms swing out, increases resultant diameter
(D) of the holder than the inner diameter of the roving bobbin tube. Thus
holds the roving bobbin in position. If bobbin along with driver ring is pushed
up, the top ends of the sprung arms resting on the ring moves right up with
them. Their bottom ends are inserted in the pivot housing, restricted by the
cylinder dimension. So, in order to follow upward push, retainer for the
bobbin swings in. The retraction of arms reduces its resultant diameter (d)
smaller than bobbin tube diameter. This helps in mounting of full bobbin or
withdrawal of empty bobbin tube from the holder.
Fiber washer is provided to minimize friction between base of arms and
housing during their spring in-out moves. The pivots cylindrical housing is
mounted on ball bearings, provides frictionless free rotation to it and thereby
the roving bobbin, suspended on it. This can help in minimizing roving
stretch. Tension finger is a steel wire loop integrated in the bearing unit on
suspension pivots and set closer to full bobbin. It acts as a light brake loop,
occasionally presses gently against the bobbin. This prevents over-rotation of
the bobbin, by not allowing it to rotate too fast. Thus acts like a brake for the
roving bobbin, so often said as brake loop.
Nowadays suspension pivots are made up of fiber material to reduce
weight and increase serviceability. Even reversal springs are incorporated for
driver rings for assured reversal. Umbrella cap provided at the top end of the
cylindrical housing prevents dropping of dirt and fly on the bearing. Otherwise
they can chalk up the bearing and obstruct its frictionless working. Due to use
of umbrella cap, this creel is also known as umbrella creel. This creel has
found space on all modern machines by overcoming all the limitations of
regular creel. As it offers following advantages:
i. It occupies less space in terms of width, offers enough lighting and
ease of maintenance and cleaning.
ii. Very large roving bobbins are used without having the fear of false
draft, due to free rotation of heavy bobbin on bearing.
iii. Having longer life and almost nil fear of getting damage.
iv. Less number of parts involved in the structure, provides considerable
reduction in storage cost.
v. Light-weight fiber material is used in the structure of suspension
pivots along with less number of accessories (support channel only).
So, less weight is born by roller beam.
Three pairs of rollers make two drafting zones (Fig. 3.4). The back zone
of the system is known as break drafting zone. The amount of draft employed
is always less but enough to remove the roving twist. This is required in order
to straighten fibers in the roving and gets them ready for receiving major
draft. In order to obtain optimum results, the break draft zone must be set in
such a way that the roving is under tension in this zone, but only sufficiently
for no real drafting to occur. This is achieved with break draft nip distances
of 60–80 mm and break draft settings of 1.03 to about 1.3. Unfortunately,
generally applicable optimum settings for every case cannot be stated, since
they depend heavily on fiber material, roving count and roving twist.
16 Engineering techniques of ring spinning
gauge of the frame. The length of the section is also referred as staff length.
Number of such individual sections are joined together in order to form long
continuous roller to suit the machine width. The roller sections fitted together
either by square joint as per older system or by screw joint as per new system.
In screw joint the screw threads engraved are opposite to that of the rotation
of roller, to prevent opening of the roller joint.
Each individual section is made from a length of round steel bar. The
portions of the roller, which are not used for drafting, are turned down to
around 2.5–3.0 mm smaller in diameter than the working section. This helps
in reducing revolving mass and thereby savings in power cost. The working
width of the roller is known as boss. It is provided with flutes for ensuring grip
on moving fiber flux. The density of flutes varies in inverse relation to fiber
flux passing through; less for back roller and higher for front roller. Bottom
rollers are classified into three categories based on flutes type:
i. Parallel flutes roller,
ii. Helical flutes roller and
iii. Knurled roller (Fig. 3.5).
Parallel flutes run along the roller axis and separated by a predefined
distance. The normally used flute density on ring frame bottom rollers is 5–6
flutes per cm. Helical flutes run at an angle to the roller axis, often referred as
spiral flues. They offer higher gripping area in comparison to parallel flutes
with the same density. Thereby provides better fiber control during drafting,
especially at higher speed and high draft levels. Knurled roller has raised points
18 Engineering techniques of ring spinning
32 27 32 (30-27-30)
also wear rather more quickly and have a greater tendency to form laps due
to the fulling effect. Harder covers are therefore used wherever possible.
However, increased control of this nature is an advantage at the delivery end,
where only few fibers remain in the bundle and these have a tendency to drift
apart. Covers with approx. 80–85° Shore are therefore usually used on the
back rollers and 63–67° Shore on the front rollers. Harder covers are also
chosen at the front, i.e. at the delivery end, for coarser yarns and manmade
fiber yarns owing to higher wear caused by stronger yarn. Even manmade
fibers show higher tendency to lap formation with soft delivery roller.
delivery end, known as tensor gap. This gap is precisely adjusted as per the
fiber volume by using different spacer plates, shoes, etc.
The aprons are made up of either leather (old) or composite technical
textile material (new). It has the width equal to the boss width of the driver
roller and thickness ranges between 0.9 mm to 1.1 mm. Endless apron is made
by tapered adhesive joint. According to the length of apron, they are classified
as either long apron or short apron.
The top aprons are always short. However, the bottom aprons can be long
aprons (Fig. 3.8(a)) or short aprons (Fig. 3.8(b)). Thus there are mainly two
categories of double apron drafting systems possible:
i. Double apron drafting system with long bottom apron and
ii. Double apron drafting system with short bottom apron
The former one is used invariably by all the drafting system manufacturers
due to its inherent advantages in terms of better performance and ease in
maintenance and cleaning.
i. Long apron: Steel Case Hardened Knurled roller is used as driver
roller for long apron (Fig. 3.8(a)). Metallic rounded tip bar is used as
guiding element for defining direction of apron in drafting zone. It is
known as nose bar. Apron tension has been controlled by either dead
weight loading (self-weight roll) or spring loading.
There is a less fear of chocking up of an apron due to more open space
available. Thereby run out will be true. Even replacement of an apron
can be done easily in the event of damage. Nevertheless, this apron
Design features of creel and drafting system variables 25
iv. Distance clip width (d): Spacing between cradle bosses for mounting
the distance clip.
v. Total width (Tw): Center to center distance of twine driver roller
aprons and
vi. Width (W): total cross wise length occupied by apron assembly.
Selection of the cradle is purely dependent on the fiber length. Cradle
length compatible with fiber length normally used in industry are as
follows:
• Short apron cradle (30–36 mm): Up to 40 mm fiber length
• Medium Apron cradle (40–46 mm): Up to 40–50 mm fiber length
• Long apron cradle (50–54 mm): Up to 60 mm
Number of elements involved in short apron is less, offering compact
structure. This permits closer setting to the front roller and offers better fiber
control. But the same makes it more inclined to become clogged with fiber
fly and dirt with the added difficulties in cleaning, if used as bottom apron.
Thereby adds to irregularities in output yarn as run out will not be true.
Even replacement of an apron cannot be done easily in the event of damage.
However, its initial cost is less due to reduced consumption of costly apron
material and number of assisting elements involved in its design.
The roller stands are made up of cast iron (on old ring frame) or aluminum
alloy (on modern ring frame). It has round or rectangular footed posts to born
the bearing for the bottom rollers. The roller stands made to incline at an angle
to the roller beam for the propagation of twist right up to the nip of front roller.
The roller stand angle varies between 30° and 45° for old version and 60° for
new version of ring frames. Its value has been defined as per the spinning
geometry of particular machine.
Front roller bearing is always kept at a fixed position on roller stand.
The rear rollers bearing are borne by the sliding bracket, fitted on the front
roller bearing housing via set screw. The rear rollers position can be altered
with respect to front roller, by altering set screw position in the slot. This
alteration is done to suit the staple length of fibers being spun. The setting
between middle roller bearing and back roller bearing is varied by set screw
connecting them together on the sliding bracket. A guiding slot is provided
behind the back drafting roller bearing for traverse bar. The traverse bar holds
trumpet shape roving guides and reciprocates within this slot. The function
of the traverse motion is to continuously move the roving guides from side
to side of the roller boss. Thereby the wear caused on drafting this fiber flux
is distributed uniformly over the large area of roller bosses. Thus it prevents
channel formation on soft roller boss and ensures its longer life span.
Nose bar and tension roller are used for the bottom apron apart from
the middle driver roller. A guiding slot between front roller and middle
roller is provided for supporting nose bar also. The support bar carrying
all the top arms is mounted in the slot provided at the back most end of the
roller stand.
The top rollers are capable of moving in the slot of top arm. Usually they
are arranged to ensure the maximum control on the fine mass of fibers at high
speed. Usually front rollers are shifted towards front with respect to bottom
front roller by 2 mm (old) to 4 mm (new), referred as front roller overlap or
overhang. The middle top rollers or aprons have given backward shift from the
respective bottom one by 2–4 mm, often said as rear over hang or an underlap.
Sometimes back top rollers have also given a rare overhang of 2–4 mm, to
ensure better fiber control at the entry point of roving to the drafting system.
The overlap of the front roller in addition also shortens the spinning triangle
by advancing the nip line, which has a correspondingly positive impact on
ends down frequency. Thus, the mathematical equation (Eq. 3.1) for front
zone setting (A) is as follows:
A = a + X + b (Eq. 3.1)
Similarly, Equation 3.2 represents the setting value for back zone
setting (B).
B = Y – b + c (Eq. 3.2)
INA Company has offered another roller configuration, so-called V Draft
drafting system as mentioned earlier. In this case the rear top roller is shifted
to the rear on the bottom roller. The larger wrapping arc (Fig. 3.12) results in
30 Engineering techniques of ring spinning
an additional fiber control zone. However, it can also result in a wider spread
of the fiber ribbon.
(b) Frame: It is a hollow channeled frame with slot/s cut at its top surface.
Loading elements and their accessories, viz., the top roller saddles
fit tightly into the top arm frame body. Thereby keeps them strictly
parallel and in perfect alignment with bottom rollers (Fig. 3.13(iii)).
Design features of frame for mechanical and pneumatic top arms
are having vast differences mainly due to their working concept.
Mechanical top arm is provided individual roller saddle fitted in
the slot of the frame with set screw. Each saddle incorporates roller
retainer to receive top roller arbour at its neck portion. The roller is
well secured in position by roller retainer flat spring. The guiding
groove (slot) gives provision to slide saddle to and fro for altering
the roller setting to suit the fiber length processed. Hence, front roller
position always remains unaltered for smooth twist flow. So, no
provision is given to alter front roller position in top arms. Sussen top
arm is provided with scale graduated in centimeter and millimeter,
parallel to the guiding groove. This helps in reading off roller setting
values directly.
Pneumatic top arm is provided with two saddles. One carries front
and middle rollers retainers, whereas second one carries back roller
retainers. There is a provision to alter middle and back roller retainer’s
positions in the guiding grooves of saddles. This facilitates to
accommodate different sizes of cradle. Both the saddles are provided
with three similar size holes punched on their surface. Saddles can
be clubbed together by matching these holes and inserting pin in one
of the hole as per requirement. This pin acts as pivotal point for front
and back roller. Such united saddles are then attached with frame via
second pin. This pin is inserted in one of the three holes punched on
both of them. This connection point again becomes a pivotal point but
now between back roller and group of front rollers (front and middle
top rollers).
(c) Loading element: It is an integral part of the frame only for both
the categories. The individual roller is loaded either by mechanical
means, viz., spiral spring (Texparts PK 225), Leaf spring (Sussen UT
600) or pneumatic pressure (Rieter FS 160 P 3.1).
(i) Spiral spring loading: SKF system uses spiral spring loading
system. Springs load roller saddles and based on its leverage,
load gets transfers to roller axis (Fig. 3.13(ii– iii)). Thus it gives
indirect mode of load transfer. A spring, sometimes two on the
front roller – presses the top roller against the bottom roller. In
the case of SKF, special load selector arrangement is provided
34 Engineering techniques of ring spinning
only for the front roller. Its loading pressure can simply be
altered with the help of eccentric load selector in three stages
by means of a tool known as wrench (Fig. 3.13(iv)). Colored
marks indicated the set loading stage. Rest of the rollers
spring pressure can be altered by separate set screw for each.
Loosening or tightening the screw can decrease or increase
the pressure respectively. But again this is head wise and in
that further roller wise manual setting, purely influenced by
individuals expertise.
(ii) Leaf spring loading: SUESSEN top arm uses refined steel leaf
spring bend at front leading edge to form plate, for loading
(Fig. 3.13(ii)). This top arm is known as the UT type. The plate
spring applies pressure directly on the roller axis. The plate
formed at the point of application also acts as damper against
roller vibration, normally occurs at high-speed drafting and
prevents roller from becoming eccentric. Spring pressure can
be altered similar to SKF with the help of individual set screw
provided for each saddle on the frame.
However cheaper, the spring loading system undergoes major
limitations. They are:
• Top arm loading pressure can be changed by set screw,
purely based on manual judgment and influenced by person’s
expertise.
• Spring looses strength with respect to time and introduces
pressure variations and thereby adversely affects quality of
yarn.
• Head wise setting mode adds to spindle-to-spindle variations.
• Roller neck gets worn out of and also roller deflection occurs,
due to abrasion with spring or loaded retainer. These reduce
roller life and reliability of alignment with bottom rollers.
Pneumatic loading: Rieter FS 160 P 3.1 is provided with
(iii)
pneumatic loading. The support bar is stamped from steel
sheet and is mounted on a continuous hexagonal section tube
behind the rollers. The tube contains the compressed air hose
connected to a central compressor unit via pressure gauge.
When pressure lever is lowered, pressure finger carried by it
forced against hosepipe via a cam. Thus it works against the
compressed air and generates pneumatic pressure (load), with
respect to its connection point with the frame. This pressure is
Design features of creel and drafting system variables 35
Figure 3.14 (a) Working elements of pneumatic top arm (Rieter FS 160 P 3.1)
Figure 3.14 (b) Load setting of pneumatic top arm (Rieter fS 160 P 3.1)
Clearers can be in the form of roller or board, and also either stationary or
revolving. Normally on ring frame revolving roller, clearers are used for top
as well as bottom rollers and aprons except bottom front roller. The revolving
clearers are basically flannel covered wooden rollers. They are bigger in
diameter than the working boss of the roller, normally 40–50 mm and as long
as the roller section. They are supported on the roller stand pins for the bottom
rollers and on roller hooks fitted on top arm for the top rollers. Common
clearer roller is employed between back and middle rollers. The clearer roller
used for the front top roller is often known as “Scavenger roller”. Cleaning on
the bottom front roller is done by pneumatic means.
Pneumafil waste
The drafted ribbon composed of all long and open fibers can go to the waste
from the front roller nip in the event of end break. So, specially designed
pneumatic system is provided for collecting these good fibers separately from
the rest of the waste generated at ring frame. Hence the system collects waste
pneumatically, known as pneumafil. The waste so collected is referred as
‘pneumafil waste” or “bonda waste”. As mentioned above it is composed off
all long, good (white) fibers in an open state, so often referred as “soft waste”
as well as “white waste”. This good fibers waste is a reusable waste even
for the same mix but never been added fully. Because undue beating of long
and open fibers, at blow room, leads towards increased yarn irregularities on
higher add on. Situation becomes more crucial with finer count spinning. So,
proportion in mix is always kept less for finer count but more for coarser count
spinning. Efforts are always made at mills to keep such waste generation as
low as possible by controlling end break rate minimum and ideally zero.
Pneumafil system
Figure 3.15 illustrates schematic diagram of one of the pneumafil set up used
on conventional ring frame. It collects pneumatically drafted ribbon on end
down from the front bottom rollers nip of the entire ring frame at one station.
So, the set up begins from front roller and ends with collection box, placed
at the tail end of the ring frame. The required air pressure is generated by
pneuma (suction) motor placed in pneumafil chamber. The circulation of the
suction air is done by the network of ducting between front rollers and suction
fan. Working principle of the system is briefly appended below:
Separate spring-loaded suction flute is provided for each head. It is kept
pressed against each bottom front roller. It draws away the ribbon of fibers
emerging from the front roller nip of the ring frame whenever end break occurs
at any head. Collected fibers follow through the extension pipe, connected to
Design features of creel and drafting system variables 39
central receptacle duct. It collects such ribbon of fibers on end break for the
entire ring frame. The end point of this duct is connected with separation
chamber, provided at the tail end of the frame. Here the fibers are separated
from the air by the conical screen. The air is expelled to the atmosphere and
waste fibers are dumped into collection tray placed at the base of pneumafil
chamber. They are collected manually via waste collection door at regular
interval of time.
ring frames are equipped with inverter controlled pneumafil motor (Fig. 3.16).
Suction pressure is set by varying inverter control pneuma motor speed in
relation to expected fiber flux flow through the system as per input data. It
purely depends on spindleage of the machine, count, and raw material being
processed. This pressure is constantly monitored by pressure transducer and
data feedback to inverter (motor speed regulating system). Thus it reduces
power consumption and prevents undue good fiber loss considerably. The
control on good fiber loss is of prime importance for high speed operating
modern machines even at the added cost of inverter control system of waste
collection.
Conventional system
The system uses cast iron gear train to drive drafting rollers from the main
drive. Draft gearing is the term relates to the gear train utilized for driving
drafting rolls only. One such schematic diagram for conventional draft
gearing is illustrated in Fig. 3.17. This gear train includes two change wheels,
viz. draft change wheel (DCW) and draft change pinion (DCP). Draft change
wheel is used to alter draft of the system, whereas draft change pinion is used
to widen the applicable draft range value of the existing system for the given
DCW. Thus the system demands larger inventory of change wheels to deal
with required draft ranges.
Design features of creel and drafting system variables 41
Whereas,
100 – % Twist contraction
Yarn count at front roller = Yarn count at bobbin ×
100
(Eq. 3.7)
for indirect yarn numbering system and
100 + % Twist contraction
Yarn count at front roller = Yarn count at bobbin ×
100
(Eq. 3.8)
for direct yarn numbering system
The setting of total draft for the drafting system is done on the basis
of mechanical draft only. Because draft relates with the surface speed ratio
of part handling delivery length (front roller) to that of part handling feed
material (back roller). Thus draft on the machine is nothing else but a surface
speed ratio of front roller and back roller.
Surface speed of front roller
Q Total draft = (Eq. 3.9)
Surface speed of back roller
Relative calculation is done by assuming unity for back roller rotation.
The length delivered by front roller is calculated and divided by the length fed
by back roller for its unit rotation.
Some important terms:
Draft constant (DC) is the total draft obtained for the unity draft change
wheel. The value of draft constant is used to determine the draft for known
draft change wheel gear or other way round, to evaluate draft change wheel
value for the known draft.
Break draft (BD) represents ratio of surface speed between front and
middle rollers. It is used for opening up the roving twist or preparing twisted
fiber strand for major draft. Higher the roving twist higher the break draft
employed for. It can be calculated and changed by replacing existing break
draft change wheel (BDCW) with appropriate size gear.
Main draft (MD) refers the major attenuation given to the parallel strand
of roving to get desired fineness yarn at front roller. Thus it represents ratio of
surface speed between front roller and middle roller.
The entire mathematic evaluation of various measures of draft can be well
understood by the example.
Example: Calculate total draft, draft constant, break draft, major draft
for the draft gearing given in Fig. 3.17. Also calculate draft change wheel
required to spin 40s Ne yarn out of 0.8 s Ne hank fed roving (Per cent Twist
contraction = 5).
Design features of creel and drafting system variables 43
33 × 21 × π × 25
Break draft = = 1.086
25 × 29 × π × 22
29 × 25 × 120 × 121× π × 22
Major draft = = 24.31
21 ×33× 50 × 11× π ×25
33 ×21 × π ×25
Break draft constant = = 31.5
25 ×1× π ×22
120 × 121 × π × 22
Total draft = = 26.4; and also
50 × 11 × π × 22
Total draft = Break draft × Major draft = 26.4
120 × 121 × π × 22
Now, draft constant =
1 × 11 × π × 22
= 1320; true for given DCP = 120
As, 40s Ne is on the bobbin with twist contraction of 5%. Since yarn
count is given in Indirect (English) system, so yarn count at front roller can be
calculated as;
100 + 5
Yarn count at front roller = 40 × = 42
100
Therefore, total draft required for spinning 40s Ne out of 0.8s Ne hank
roving is
42
Total draft = = 52.5
0.8
According to relationship
Draft constant
Total draft =
Draft change wheel
Draft constant
or Draft change wheel = (Eq. 3.10)
Total draft
The required draft change wheel in present case is,
Draft constant 1320
Total draft = = = 25.15T ~ 25T
Draft change wheel 52.5
So, 25T draft change wheel (DCW) should be used to get desired 40s Ne
yarn out of 0.8s Ne hank roving fed.
Now it is clear from this example that exact draft value is difficult to meet
in many a case in this type of set up. As gear with partial teeth (25.15T) is not
possible, it needs to be rounded off to the nearby full number (here 25T) as
per math’s rule. Such draft gearing gives draft either on higher side or lower
44 Engineering techniques of ring spinning
side as per the position of change wheel gear in the train (driver/ driven). As
in the given example rounding off of gear value gives draft of 52.8 instead
of 52.5 desired. Thus, actual yarn spun is of 40.13s Ne instead of desired 40s
Ne fineness. This deviation in yarn fineness is attributed to the limitation of
exactifying gear value.
The entire discussion highlights following limitations of convention drive
set up:
(a) Requires different size gears for BDCW, DCW and DCP while
working with different roving twist and yarn size, increases need for
inventory of parts.
(b) Change of break draft or draft demands mathematical calculations.
Adds to time delay and associated human error.
(c) Due to limited availability of alternatives with two change wheels,
allowable draft range gets limited, limits spinning range of ring frame.
(d) Change over is time consuming, tedious, increases downtime of
machine. It is also suffering from associated human errors and
rounding off errors in mathematically derived gear values. Thus
liable to vary yarn size more from the nominal one.
(e) Long-gear train composed off heavy cast iron gears adds to power
cost. Also demands regular maintenance, increases machine down
time also.
(f) Spur gears used for the drive have incorporated inherent slippage in
drive, varies the roller speed from the theoretically set one results in
draft variation.
weight cast iron gears, thereby given low maintenance and longer shelf-life.
All together has allowed high speed draft with high draft ratio possible on
ring frame. High draft ratio has permitted to spin with coarse feed hank.
Speed frames can operate at high speed for coarser roving. Thus increased
production per flyer frame and reduced number of flyer frames needed at the
back, added to process economy.
Here high speed drafting refers drafting done at increased delivery speed
but at the same speed ratio of rollers. So, fineness of feed material and output
yarn remain identical. High draft ratio means drafting done by maintaining
the same delivery rate but at increased speed ratio of the rollers. Thus for
producing yarn with similar fineness, coarser roving can be used.
The system still suffering from the following limitations:
(a) Initial cost of the system is high; no doubt its payback period is less.
(b) Still manpower is used in gear change, although simplified liable to
introduce human error.
(c) Single motor situated at head end is used for the entire machine drive.
Differential torque developed between head end and tail end likely
to cause twisting of bottom rollers’ shafts. The situation becomes
more critical with longer length (1600 or more spindles) machines
operating at high speed.
at the center also. Owing to the mode of functioning, the system often referred
as, ‘frequency converter controlled individual draft roller drive system’. No
doubt capital investment for the system is much higher.
Figure 3.18 Frequency converter controlled individual draft roller drive system
twist barrier and will not allow it to propagate closer to the front roller nip.
This always results in the twist less triangular bundle of fibers often called
“spinning triangle”.
The angle formed between exit and entry point of fiber bundle with the
center of the bottom front roller is known as angle of wrap. It varies in inverse
relation to the inclination of the drafting system. Higher the angle of wrap,
more it will act as twist barrier and twist flow gets restricted earlier before
reaching to the nip of front roller. Hence, larger spinning triangle forms longer
length of weak band and increases end breakage rate.
On the contrary, higher inclination of the drafting system makes spinning
triangle too short. Edge fibers undergo longer path line, escapes from the
proper binding of the twist. Short fibers do not bind at either end and lost into
atmosphere as fly, whereas long fibers get bind at one end only leaving other
end protruding out from the yarn surface; thus produces hairy yarn.
Proper selection of drafting system inclination must be done as per desired
spinning geometry. It should give good binding of edge fibers with yarn
matrix to avoid hairiness and fly generation, also there should be minimum,
ideally zero, end breaks throughout the doff.
48 Engineering techniques of ring spinning
3.4 References
1. Carl A. Lawrence (2003). ‘Fundamentals of Spun Yarn Technology’, CRC
Publications.
2. De Barr and Catling H. (1965). ‘Manual of Cotton Spinning: The Principles and
Theory of Ring Spinning,’ Manchester, The Textile Institute.
3. Eric Oxtoby (1987). ‘Spun Yarn Technology’, Butterworths & Co. Ltd., London.
4. Gilbert R. Merrill (1959). ‘Cotton Ring Spinning’, Mass, Gilbert R. Merrill, Library
of Congress catalogue card number: 59-10906.
5. Klein W. (1987). ‘The Manual of Textile technology: Vol. I –The Technology of Short
Staple Spinning’, Manchester, The Textile Institute.
6. Lord P.R. (2003). ‘Hand Book of Yarn Production: Science, Technology and
Economics’, Taylor and Francis.
7. www.rieter.com/.../ring...drafting-system/.../double-apron-drafting-system.
[Accessed on 1 June 2014].
8. http://www.components.oerlikontextile.com, [Accessed on 1 June 2014].
9. http://www.suessen.com/fileadmin/suessen/products/EN/ring-spinning/hp-drafting/
technical-memos/hp-a_410_top_weighting_arm_sct3214ne_1106.pdf, [Accessed on
1 June 2014].
10. http://www.nptel.ac.in/courses/116102038/23, ‘Latest Development in Ring Frame -
nptel [Accessed on 1 June 2014].
11. http://www.academia.edu/3773342/Developments_in_drafting [Accessed on 20
September 2014].
4
Twisting mechanism
4.1 Introduction
Drafted ribbon emerging out of front roller nip at ring frame is the finest
amongst all outputs of drafting system over the entire spinning process.
Thereby additional strength is imparted by compacting constituent fibers of
ribbon together by inserting twist. Ring–traveller set is used for generating
desired turns of twist. However, some bulk (cover) and elasticity of the strand
gets sacrificed in the course. So, amount of twist inserted gets vary for different
end uses. Such yarn need to be wound on a suitable size package, compatible
with existing as well as next machine set up in sequence for ease of material
handling. Even winding needs to follow peculiar pattern again suitable for
next process in a sequence. The brief mention about various machine parts
involved in the entire course of spinning, winding and bobbin building is
given in this chapter.
to obtain desired strength value and prevents tendency to fray apart. A brief
mention of twisting mechanism used on ring frame is appended below:
A low-twisted bundle of parallel fibers (the roving) is fed to the drafting
zone. The difference in surface velocity of the front (faster) and back (slower)
drafting rollers will attenuate it to a desired fineness thinner strand of parallel
fibers, under the control of the double aprons. The thin strand of parallel fibers
emerging from the front rollers is then simultaneously twisted by upright
twisting. The turns of twist are generated by the ring–traveller combination.
Where, ring is acting as a track for the traveller, roaming on its periphery. One
rotation of traveller earns one turn of twist for the drafted strand. Traveller is
driven negatively by the pull of yarn generated due to the difference in spindle
speed and winding speed (front roller delivery speed). The twisted thin strand
of fibers, now called a yarn, is threaded through a traveller and a yarn guide and
balloons out between these two elements during normal spinning. The twisted
yarn is then wound onto the bobbin or yarn package (i.e., cop) mounted on a
driven spindle (Fig. 4.1 (ii)). The bobbin is encapsulated within the rotating
balloon formed between yarn guide and ring–traveller.
lappet guide and ring–traveller, induces yarn tension. This tension should not
exceed yarn strength, otherwise results in end down. Balloon tension control
devices like Anti Balloon Control (ABC) ring and separator are employed for
the purpose many a times. But they are not a mandatory feature of twisting
mechanism. Either both or one of them is used as balloon tension control
device for imparting spinning stability.
screw. The guide wire is adjustable in the slit for desired alignment with the
spindle, bobbin and ring. Guide eye is either easy threading or self-threading
in nature.
Lappet: Lappet is designed to support the thread guide. It is a flat square
or rounded square metal plate. Its back end is hinged on the thread guide rail
for lifting it independently, primarily for piecing up. Spacing between the
adjacent lappets is enough for the passage of the separators during traversing.
Thread guide rail: Thread guide rail is either a continuous round roll
or flat rectangular cross section metallic strip. One rail per side, of the ring
frame is provided to support the respective group of lappet guides. It is kept
in housing just in front of roller beam, with the top surface about level with
the upper surface of the roller beam. Handle is fitted at each extremity, to lift
half of the guides on a one side of the frame simultaneously. This is mainly
required at the point of doffing.
angle value. Since spinning is done in the vertical plane, the angle so formed
between front roller and the lappet guide by the yarn path with vertical
spinning axis is known as spinning angle (γ). As per spinning geometry it can
be evaluated as;
X
tan (γ) = [Eq. 4.1]
Y
Thus spinning angle can be varied by either changing horizontal
displacement (X) or vertical displacement (Y) of lappet guide. However,
its horizontal position cannot be altered, otherwise disturbs centering with
spindle (Fig. 4.1 (v)). On the other hand, vertical displacement is continuously
changing during bobbin build up due to traversing and advancement performed
by thread guide rail.
• Farther the lappet guide to front roller [larger X], spinning angle (γ)
formed will be small. But it acts more as twist barrier due to increased
angle of contact at lapper guide. Thereby twist flow stops earlier and
forms larger spinning triangle. Presence of longer twist less band or
longer weak band, increases chances of end breaks.
• Closer the lappet guide set to front roller [smaller X], spinning
angle (γ) formed will be large. But it acts less as twist barrier due to
reduced angle of contact formed at lapper guide. Thereby twist flow
moves closer to front roller nip and forms smaller spinning triangle,
represents smaller twist less or weak band. Thereby chances of end
breaks due to low strength get reduced at this end. However, higher
deflection of edge fibers increases stress on edge fibers to get bind
with core and either protrude them out, or increases fly generation.
Thus value of spinning angle (γ) must be retained within desired limits for
controlled yarn quality and spinning stability. It is ranging between 17 and 35
degrees according to spinning geometry of modern ring frame.
Thus the contribution of lappet guide in ring spinning can be summarized
as:
i. The thread guide is acting as guide during changeover of the plane,
viz., inclined drafting plane to vertical spinning plane.
ii. Its vertical position with respect to front roller defines spinning angle
(γ), angle of wrap at front roller and also spinning triangle. Correct
selection of these parameters facilitates easy flow of twist without
any obstruction right up to the nip of front roller.
iii. Vertical distance of lappet guide from ring defines balloon height.
Balloon height has a major share in defining spinning tension as well
as spinning stability.
54 Engineering techniques of ring spinning
4.3.2.1 Separators
If too wide balloon forms during spinning, causes slashing of the balloons
and results in multiple end break as mentioned above. Slashing of balloon
refers striking of adjacent balloons with each other. This is totally undesirable
phenomenon for ring spinning as it increases downtime of the machine as well
as hard waste. So, it becomes necessary that yarn balloon diameter (D) must
be controlled within limits. Separators are provided for this purpose between
two neighbouring spindles (Figs. 4.2 (i–ii)). As the name suggests it keeps
adjacent balloon separate from each other.
Separator is a thin metal plate, of different shapes, rectangular, oval etc.
It is used to prevent balloon slashing, so, always located halfway between
adjacent spindles above the ring rail. They were made up of thin sheet steel
plate with large slits punched on it to reduce the weight on old ring frames.
But nowadays it is made up of light weight sheet aluminum or plastic without
any need of punching. The surface of the separator is made highly smooth to
prevent yarn damage on striking with this surface.
These separators are operated by a separator bar (lifter rod) supported
by a bracket on the ring rail. This bracket can be adjusted to vary the travel.
Separators are readily tipped back for doffing, and a guard attached to the
roller beam knocks them back into position if the frame is started while they
are tipped back.
Automatic type separators are the fixed type of separators. This type, as
illustrated in Fig. 4.2(iv), is attached to the ring rail by means of a bracket.
They can be tipped back in the same manner as the type above described. This
style is always in a constant position relative to the ring rail.
Although separators are designed to control balloon geometry and thereby
spinning tension, they possess some inherent disadvantages. They are:
i. The yarn forming the larger balloon gets strike with the metallic
separator. It can prevent undesirable striking between adjacent yarns
but beating against the surface itself is disadvantageous. It gives rise
to napping of the thread, formulation of fly and molten spot formation
for the manmade due to abrasion.
ii. Doffing becomes difficult, as separators are located in the way to doff
the bobbins from the spindle. So, they need to be tipped back from the
bobbin withdrawal path.
• If they have swing back at the time of doffing need to swing
forward into the proper running position as the frame makes
the first traverse after doffing.
56 Engineering techniques of ring spinning
winding position of the yarn. The angular and vertical winding positions
are altered by the relative displacement of traveller on the ring and ring rail
position respectively. Ring rail is the movable support frame for rings. It
traverses up and down to guide the yarn onto different parts of the bobbin, to
get desired pattern of bobbin build up.
The vertical height (b), formed below the horizontal top part is known as
“web”. This web is quite thin enough to allow free friction less rotations to the
traveller, although its ends may be close together, but still clear the web. Web
thicknesses (t) ranges normally around 0.8–0.85 mm.
The horizontal top part of the ring is referred as “flange”. It should be
broad enough to prevent lifting away of the revolving traveller from the
web. But at the same time it should not too wide to make traveller mounting
difficult. Thus one of the criteria considered in the selection of right traveller
is its compatibility in fitting on the ring flange on which it runs.
4.3.3.2 Classification of ring
There are different ways to make distinction for types of spinning ring. They
are briefly mentioned below:
58 Engineering techniques of ring spinning
Normally preferred for the travellers having larger circle, as they are
more prone for tilting.
• Ribbed web rings: These rings have a rib around the center of the
web, sometimes on the inside and at the other times on both inside as
well as outside. This adds to the surface are of the ring for the ease of
heat dissipation.
However, all the modern rings are single flange type with marginal
changes in their structure to deal with high speed spinning.
traveller for finer count on rings with medium or wide width flange would
have to be made from such a finer wire that it would quickly wear or spring
off the ring. On the other, if coarser yarns should be spun on narrow flange
rings, the traveller should be made of heavy gauge broad wire. Such traveller
would be difficult to manage on narrow flange ring. Consequently, in general,
narrow width rings are used for finer yarn and wider flanges for medium and
coarse yarns.
Height of ring: Different manufacturers have slightly different base
dimensions and tolerances for the rings. Although the rings have identical
diameter and flange width, they do not fit properly in a given ring holder. So,
mention of ring height is necessary along with diameter and flange width for
its true identification.
The height of ring generally ranges from 0.3125 mm (old) to 0.3750
mm (new). The height adds to the area available for the heat dissipation. So,
modern ring frames operating with higher speed, liable to generate more heat
due to friction, are normally provided with rings with more height.
*Lubricating film: It refers thin film builds up of cellulose and wax. This
material arises from material abraded from the fibers. If fiber particles are
caught between the ring and traveller, then at high traveller speeds and with
correspondingly high centrifugal forces, the particles are partially ground to
a paste of small, colourless, transparent and extremely thin platelets. These
platelets are continually deposited on the running surface of the ring, offering
smooth surface to revolving traveller and reduces friction between them.
Thereby it is known as lubricating film. These platelets are also replaced
continuously during working.
The position, form and structure of lubricating film depends on
• Yarn fineness
• Yarn structure
• Fiber raw material
• Traveller mass
• Traveller speed
• Height of traveller bow
Material: Rings are made up of a case hardened high grade steel alloy.
Owing to their higher hardness, traveller change frequency was too high
on modern high speed ring frames. Modern rings usually feature a surface
coating. The object of such coatings is mainly to reduce friction and wear.
Addition to this it also prevents corrosion and simplifies running-in the ring.
Coatings used include:
• Oxides
• Nitriding
• Carbonitriding
• Hard chrome
• Nickel (in some cases containing hard particles)
• Ceramics
The currently customary ring material is Carbon-Nitride coated
(Carbonitriding) high grade steel alloy.
Manufacturing process:
It includes following steps:
(a) Machining: Seamless tubes with desired height are prepared out of
the selected raw material as per manufacturer’s need. They have
given desired inner and outer shape and profile on special lathes with
the help of different tools.
(b) Hardening: It is carries out either by: (i) through and through
hardening (old); or (ii) case hardening process (new).
Twisting mechanism 63
(c) Polishing: This makes the ring smooth. Special machines hold and
revolve the rings and fine abrasive (powder or paper) abrade them.
A coolant liquid may be optionally used. Without coolant, the ring
may lose hardness at high temperatures generated in the course.
The finishes may be (i) Matt or Satin finish (micro etching) and (ii)
Chemical or Electrochemical polishing (Rough and dull effect). A
black film of iron oxide having 0.0127 mm thickness is applied in
chemical process. Whereas metal is removed from the surface before
application of film in electrochemical process.
(d) Inspection: Rings are thoroughly checked for uniformity of hardness,
surface, ovality and cracks.
4.3.3.5 Mounting of rings
Rings, so manufactured are mounted on a ring rail. The ring rail is a cast iron
(old) or steel (new), long, narrow, channel-shaped metal plate, the length of
one side of the ring frame. It is bored with holes at regular intervals to match
with the spindle gauge. These holes are concentric with the spindle and are
large enough to accommodate spinning rings or ring holders. The rail is held
in a horizontal plane keeping the flat side upward. The rings are mounted in
these holes by one of the following methods:
(a) Direct mounting: Common rings are directly mounted on ring rail.
They are essentially single flanged rings, with the lower portion
extended long enough to pass through the hole on the ring rail. The
projecting edge of the ring, on its outside (Fig. 4.3 (ii)) and at the
middle of the web capable of supporting it at the top of the ring rail.
One or two screws are used to secure the ring right into the position
on ring rail.
(b) Indirect mounting: The rings other than the common rings do not
have the outward projection for the direct mounting. They have small
outward projection at the bottom end. This can help in securing them
on the holders (supports), fitted into the ring rail holes. They are
known as ring holders and of two types: (i) Cast iron ring holder and
(ii) Plate ring holder (Fig. 4.3 (iv)).
(i) Cast iron ring holder: The holder is made up of cast iron ring. It
is having outer bottom diameter turned down to the correct size
to fit freely into the holes of the ring rail. The inside diameter
of the holder is slightly larger than the size of the ring it holds.
The upper outside edge of the holder is rounded over and made
larger than hole. Thus the projected top edge supports the ring
holder fitted inside the hole from the top. The holder has a
radial cut on its one side. This provides spring type action to
64 Engineering techniques of ring spinning
hold the ring. The holder along with ring held inside is inserted
in the hole of the ring rail till the top projection sits on the rail.
One or two screws are inserted from the front end of the ring
rail to grip the holder firmly.
(ii) Plate ring holder: It is a sheet steel stamping; circular,
square or oval shape with rounded corners. It is not inserted
inside the hole but remains at the top face. It’s all outside
dimensions are thereby large enough to cover the hole of the
ring rail. The inside diameter of the holder is slightly bigger
than the outside ring diameter it holds. Two notches are
punched diametrically opposite edges to receive the screw,
which fasten the holder to the top of the ring rail. Two-three
small metal sections, known as lugs, spaced at equidistance
radially on the circle having the diameter smaller than the
bottom rounded edge of the ring. These lugs are designed to
hold firmly the lower portion of the ring. When necessary, the
rings may be pressed out easily, as the holder hole is larger
than the ring diameter.
Both the types of holders are also available with different inside diameter,
keeping outside diameter same. This can help in dealing with smaller size
rings on same ring rail. Sometimes sheet metal bushes are used to reduce
the inside diameter of the same holder for small diameter rings. This gives a
further cheaper option to deal with different size rings on the same machine
set up.
iv. Take new correct set of traveller and run the ring frame for entire doff
at the speed < 30 m/sec. Then remove all the travellers and clean all
the rings with clean cotton. Check all the travellers for blueing of
travellers.
• If %burnt travellers < manufacturer’s recommended 15%, set
the spindles to normal speed and replacing travellers with new
correct set continue with regular spinning.
• But if %burnt travellers > 15% repeat 4th step until desired
level is achieved.
4.3.3.7 Modern high speed rings
The conventional T-shape rings were used along with C-shaped traveller.
Although this combination was offering pretty good yarn clearance, required
to avoid yarn hairiness, suffering from the major draw-backs associated with
traveller canting.
Traveller canting: The center of gravity of the traveller is usually above
the horizontal axis of the ring flange. So, the centrifugal forces caused on
ballooning make the upper and outer part of the traveller to tilt downward
to bring down the center of gravity of the traveller into a horizontal line of
the ring flange. This tilting causes the outer horn of the traveller to come in
contact with the outer surface of the ring web to prevent further tilting. This
phenomenon is referred as traveller canting, often said to be “back tracking”.
Extent of canting is in proportionate to traveller circle size. Frictional
contact of traveller horn with the ring web increases heat generation and thereby
limits allowable spindle speed. Thus interaction between ring and traveller
during running conditions imparts limitations to ring frame productivity. They
are overcome in modern high speed ring and traveller design features. The list
of rings used on modern ring frames is given below:
• Anti-wedge ring
• SU rings
• Orbit rings
• Sintered rings
• Rotating rings
Since ring–traveller works in combination the structural changes are
justified in interaction with respective traveller design in forthcoming section.
4.3.4 Traveller
Traveller is the hardened, tempered, scoured and polished piece of steel wire,
bent to get desired shape (C-shape, for conventional). This shape allows it
Twisting mechanism 67
to fit loosely on the ring flange and races on its circular path by the yarn
pull. Rotations of traveller insert turns of twist to the drafted strand of fibers
emerging out of the front drafting roller nip.
Traveller does not have a drive on its own, but yarn drags it along the ring
periphery. However, traveller speed legs behind by the spindle speed. Traveller
and spindle together also help to wind the yarn on the bobbin. Traveller guides
the length wound up on the bobbin. The winding length corresponds to the
difference in peripheral speeds of the spindle and traveller. The difference in
speed should correspond to length delivered at the front rollers.
Hence its weight is too low in comparison to rest of the parts involved
in spinning, but reasonably high enough for yarn on which it rests. The force
generated by its weight on yarn during twisting determines balloon size
and thereby spinning stability. Even its weight determines winding tension
and thereby compactness of ring bobbin. Although seems very minute in
appearance, it plays a major role in success of spinning, viz.
• It imparts twist to the drafted strand.
• It guides the yarn for winding onto the cop.
• It defines spinning tension and winding tension.
The circle of the traveller must be large enough to readily clear off the
flange of ring on which it runs by giving enough room for yarn passage.
However, for any given weight of traveller, as the circle is larger, the wire
gauge used must be finer. The finer the traveller wire, the more quickly
traveller gets worn out. So, balance must be kept between traveller circle and
wire gauge used.
Twisting mechanism 69
These travellers are then carefully hardened and tempered, after which they
are scoured to remove rough edges and then polished. Final critical inspection
is done before packing and dispatch.
Other materials used are:
i. Brass alloy: It is used for wet doubling of cotton. These travellers must
be used along with lubricating rings only; otherwise ring–traveller
friction will be high due to transfer of brass on the ring surface.
ii. Nylon: Nylon travellers are widely used for spinning cotton, worsted,
woolen, man-made fibers, jute and glass. Due to its higher coefficient
of friction, they are made lighter to acquire desired yarn tension during
spinning. However, this adversely affects stability of traveller on the
ring during running. Spinning stronger materials like manmade fibers
or animal fibers wearing out of nylon will be faster due to higher
yarn–traveller abrasion. In such cases nylon traveller with metal
insert is used.
Additional treatment of the material: Selecting correct material for
the traveller amongst all, for qualitative and quantitative spinning is quite
important. It is based on the extent, the traveller can fulfill following
requirements:
• Generate as little heat as possible
• Quickly distribute the heat that is nevertheless generated from the site
where it occurs (contact surface) to the traveller as a whole
• Dissipate the heat quickly to the ring and the air
• Be elastic, so that the traveller can be pressed onto the ring without
breaking
• Display high wear resistance
• Have a slightly lower hardness than the ring, since the traveller must
wear rather than the ring.
Steel has found superior amongst all. Therefore travellers used in short
staple spinning are made almost exclusively of steel. However, pure steel does
not ideally fulfill the first three requirements. Traveller manufacturers have
therefore been attempting for decades to improve running conditions through
surface finishing. The various methods used for the purpose are:
(a) Electroplating, in which the traveller is coated with one or more
layers of metal, such as nickel, ceramic and silver, or
(b) Chemical treatment to change surface properties in order to reduce
friction and scoring.
(c) Diffused finishing treatment into traveller surface. The Bräcker
company has developed this process for introducing certain treatment
Twisting mechanism 71
i. The traveller must be shaped to match exactly with the ring in the
contact zone, so that a single contact surface, with the maximum
surface area is created between ring and traveller.
ii. The bow of the traveller should be as flat as possible, in order to keep
the center of gravity low and thereby improve smoothness of running.
However the flat bow must still leave adequate space for passage of
the yarn
The traveller shapes used in short staple spinning (Fig. 4.6 (i)) are:
(a) C shape travellers
(b) flat or oval travellers
(c) elliptical travellers
(d) N travellers and
(e) ORBIT travellers r
becomes too large, the cop too soft and the amount of material taken up on
the cop too small. On the other hand, too high a mass results in high thread
tension and frequent ends down. The mass of the traveller must therefore be
adjusted exactly to the yarn count, tenacity and the spindle speed. If there is
a choice between two traveller weights, the heavier one is usually preferred,
since this results in higher cop weight, smoother running of the traveller and
better heat dissipation.
The traveller weights are determined beside the yarn number by material
being spun, yarn strength, spindle speed, yarn count and spindle speed. Their
relationship has been illustrated in Table 4.2.
staple spinning. The low arch travellers are often referred as “Elliptical
travellers”, as their rounded major part consists of an ellipse.
Manufacturers have done modifications to a given type of an arch to
meet fancied needs. These efforts have given special categories of travellers
(Fig. 4.7) as follows:
(a) Double duty travellers: They are made by punching out a small
elongated oval hole in the center of the top of the arch. Normally
done for medium and heavy weight travellers. Elimination of metal
weight at the top of the arch lowers down center of gravity and brings
it nearer to the horizontal plane of the ring flange. Thereby minimizes
tendency of traveller canting and facilitates in reducing ring–traveller
friction. Apart from that it also helps in reducing lint collection on the
traveller. Different manufacturers have given different name to this
modification made, such as “Comet”, “Split Back”, “Imperial” and
“Perforated Bow”.
(b) Gravity travellers: Small quantities of steel have been ground away
from the side of the wire at the top of the arch. Commonly done for
fine travellers. This modification reduces traveller weight further
without affecting circle of traveller and wire gauge. This can facilitate
76 Engineering techniques of ring spinning
Celsius. This has to be dissipated in milliseconds by traveller into the air. But
low mass of the traveller does not permit dissipation of the generated heat in
the short time available.
If spindle (/traveller) speed is raised beyond normal levels, the thermal
stress limit of the traveller also get exceeded, a drastic change in the wear
behaviour of the ring and traveller ensues. The heat so developed soon burns
the traveller, makes it bluish and brittle. Such traveller will either fly off the
ring or breaks, results in end down. Excessive “end down” in spinning room,
makes work of operatives and waste control difficult. This adversely affects
quality of yarn produced and efficiency of spinning room.
Beyond the thermal stress limit of the traveller, adhesion forces between
ring and traveller get strongly increased, likely to cause welding between the
two. These seizures inflict massive damage not only to the traveller but to
the ring as well. The traveller temperature even reaches 400°C to 500°C and
the danger of the traveller annealing and failing is very great. All together
restricts the operating speed of the traveller and thereby spindle. Limitations
in increasing spindle speed results in reduced production rate of the spinning
department.
The maximum attainable speed of traveller without getting damaged
is known as “limiting speed of traveller”. It is 70 ft/sec. (22 m/sec) for
conventional set of ring–traveller and 145 ft/sec. (42 m/sec) for high speed
ring–traveller.
pronounce with the use of heavy traveller. So, running-in cycles for
the ring must be planned accordingly for retaining desirable ring
surface characteristics.
Angle of pull: It is an angle (Ø) formed between tangent drawn to
iv.
yarn path from traveller to bobbin and line passing from traveller to
bobbin axis, also known as “winding on angle”.
The angle of yarn pull decides the magnitude of forces acting on traveller
(Fig. 4.8). Yarn has been led through traveller to the bobbin for winding.
Bobbin is mounted on the spindle and driven positively. It pulls the yarn from
the front drafting roller nip by winding force (F) at an angle (Ø). The axial
component (F Cos Ø) keeps traveller pressed against the ring, not allow it to
fly off the ring against the balloon force. The tangential component (F Sin Ø)
lifts traveller against the ring and rotate around the ring. Thus yarn tension
at the point of winding dependent on the tangential component of winding
force. Hence Sin Ø = r/R, for the given ring diameter (R), it depends mainly
80 Engineering techniques of ring spinning
on bobbin radius (r) or bobbin diameter. In the beginning of doff (Fig. 4.8
(ii)), yarn is wound on the smallest bobbin diameter (re) results in smallest
value of ” but highest value of “Cos Ø1 ” component. Thereby, yarn has to
work more to rotate the traveller around the ring. This increases yarn tension
and end down frequency. Whereas at the end of the doff, winding takes place
on full bobbin having highest radius (rf) value, thereby highest angle of pull
“Ø2”. This reduces axial component quite considerably but build up higher
tangential component of pulling force. Thus, yarn has to work less to rotate
traveller, reduces yarn tension.
The yarn tension is reasonably high with a small angle of pull, likely to
cause end breaks. If yarn is not strong enough to sustain the stress, end breaks
will be frequent and adversely affect spinning stability. The situation is more
crucial with the use of larger diameter ring and smaller bare bobbin diameter.
So, good commercial spinning conditions demand the minimum angle of pull
to be kept 23 degrees. Satisfactory spinning conditions can be attained while
working with an angle of pull ranging between 23 to 35 degrees.
Technological guidelines for the traveller selection
(a) When the ring diameter is less, balloon diameter will be small. This
leads to more yarn tension. Hence use lighter travellers.
(b) When the ring diameter is bigger, balloon diameter will be more.
This leads to less yarn tension and the balloon touches the separator.
Hence use heavier travellers.
(c) When the tube length is short, the yarn tension will be more. Hence
use lighter travellers.
(d) When the tube length is long, the yarn tension will be less, hence use
heavier travellers.
(e) When the yarn contact area and ring contact area in traveller is closer,
fiber lubrication is better, especially in cotton. For this use heavier
travellers.
(f) When spindle speed is increased use lighter traveller with low bow
height. At higher speeds, lighter travellers give lesser yarn tension.
When low bow height travellers are used center of gravity will be
closest to the ring which aids in running of traveller.
(g) Use lighter travellers on new rings. This is done to reduce end
breakages by reducing the yarn tension.
(h) Use heavier travellers on old rings. This is done to avoid bigger
balloons.
(i) Heavier travellers reduce hairiness.
(j) When using lighter travellers, yarn stretch will be less. It helps for
Twisting mechanism 81
So, anti-wedge ring has been designed. It has ring flange with a flared inside
surface and is flattened off considerably on top. This change in shape enabled
a ring–traveller with a low center of gravity, precisely adjusted arc for smooth
yarn passage and increased contact area during running (Fig. 4.9 (ii)). Thus
the combination provides greater bearing surface for the traveller and helps in
rapid heat dissipation by spreading the heat over a wider area. This can permit
the traveller to run faster up to 30 m/sec without getting over heated.
This combination retains all the advantages associated with anti-wedge ring-
elliptical traveller.
The arc of the traveller could also be flattened off further, to make use of
oval traveller/flat traveller with such ring for spinning finer counts. Further
lowered center of gravity permits better running condition for the traveller, fit
like clip on the ring.
Inclined/oblique ring: Ring flange has been made inclined instead of flat
horizontal one to increase the surface contact area between ring and traveller.
This type of ring was first invented in Russia and marketed as the “SU ring”
in 1960.
as well. For the identical yarn tension, i.e. same frictional forces, 10–15%
lighter travellers can be employed for SU rings in comparison to T-flange
rings. The loading of ring–traveller can be further reduced thereby results in
higher speed potential of the traveller up to 15%. The use of lighter traveller
for oblique ring can be well explained from the geometry of the forces
(Fig. 4.10 (i)). In the steady state of traveller, the forces centrifugal force
(Z), yarn tension (S) and normal force between ring and traveller (N) acting
on it in the plane through the spindle axis forms a closed triangle of forces.
This triangle of forces is of general validity for the given balloon conditions,
irrespective of ring–traveller system employed. With T-shape ring there is a
single normal force FN (Fig. 4.10 (ii)), between ring and traveller. However
it has been divided into two components N1 and N2. Vector wise the sum of
N1 and N2 is equal to normal force N; that is N = N1 + N2. But scalar wise it
exceeds N, that is; N < N1 + N2. Hence the frictional forces caused by the
normal forces: µN < µN1 + µN2 or R < R1 + R2.
Thus under the same working conditions, i.e. traveller mass and
coefficient of friction, oblique ring offers higher frictional force on the
traveller. Consequently for the same yarn tension, lighter travel should be
used with oblique ring–traveller as compared to T-ring–traveller.
Summarizing the discussion, with oblique ring–traveller two major
advantages can be earned:
• Significantly bigger contact surface area between ring–traveller, and
• Use of lighter weight traveller.
Yet this system has not found commercial success despite of its advantages.
That is mainly attributed to its following limitations:
i. Surface contact area (A1) between straight profile of the ring and
traveller available for absorbing force N1 is indeed large enough. But
the surface contact area (A2) available at the top rounded edge of
the ring is very small for absorbing force N2. As a result the surface
N2
pressure (P2 = A ) in the range of force N2 is much higher than
2
N1
surface pressure (P1 = A ) in the range of force N1. Although surface
1
research done by Rieter. This has not only reduced wearing out of rings
at top but also minimized traveller’s thermal loading significantly.
Spinnability of fine yarns: Spinning fine yarns with inclined rings
2.
successfully became indeed difficult in case of SU-ring due to use
of longer wire length as compared to C-shape traveller. So, SU-ring
profile needs to be modified in order to reduce required wire length.
The collar height of SU-ring was reduced substantially to shorten
both the legs of traveller used for it considerably (Fig. 4.10 (ii)). As
a result orbit ring traveller length is negligibly longer than C-shape
traveller for T-ring with 3.2 mm flange width (used for fine counts).
This has enabled orbit rings to spin comfortably finer counts.
Twisting mechanism 87
This can allow ring frame to operate at 30% higher spindle speed
(Ns). Hence limiting speed of the traveller is high, practically higher
spindle speed can be attained, gives increased production rate and
thereby reduced yarn cost/Kg.
Longer life span of ring–traveller: Higher area of contact uniformly
8.
distributed between traveller legs in contact with ring, imparts
uniform pressure. Uniform wearing out of the ring thereby offers
15% longer life span of ring as well as traveller even at higher
spindle speed.
Improved yarn quality: Higher operating speed of the spindle (Ns)
9.
gives rise higher yarn tension (S), as S ∞ Ns3. Higher yarn tension
increases height of node (πP), permits higher balloon height (H),
without causing balloon collapse. Thereby spinning becomes
possible without any need of balloon control ring, liable to cause yarn
damage especially introduce hairiness on rubbing. Thus improves
product yarn quality. Spinning at higher tension also improves fiber
orientation and thereby increases product yarn strength.
4.4 Twist
Twist as mention in the beginning, refers spiral turns given to the parallel
strand of fibers for imparting cohesive forces amongst them. The brief mention
about the two important phenomenon, viz., direction of the twist and amount
of twist needs to be defined in relation to ring spinning.
Twisting mechanism 89
If the spirals of helical configured yarn, matches with the central portion of
letter ‘Z’ then it is said to be a ‘Z-twist’. It is often said to be a ‘Regular’
or ‘Right hand twist’, as inserted due to the clockwise rotations of the fiber
strand. Single yarns are usually Z twisted, so also referred as ‘Single yarn
twist’.
broadly classified into two groups: (i) Single motor operated ring frame and
(ii) Multimotor operated ring frame.
setting, although done manually (Figs. 4.11 (iii) (c–d)). This arrangement has
permitted faster and precise change over for the twist direction for the single
motor driven ring frame.
The spindle speed is always set at a maximum speed. So, higher yarn
twist can only be obtained by reducing delivery speed. Generalizing, higher
twist can be inserted while working at low production rate. This is further
made clear with an example.
Example: Calculate yarn twist (tpi) for the twist gearing given in
Fig. 4.12(ii) [where, A = 45T, B = 24T, C = 32T and D = 55T].
Now,
Spindle speed (rpm )
Yarn twist (tpm) = [Eq. 4.6]
Delivery speed (m/min )
Hence twist gearing involves information about driving gear train between
spindle and front roller, responsible for twisting only. Relative calculation
need to be done for evaluating yarn twist. Accordingly for unit revolution of
front roller spindle speed is calculated by using gear train. So, Equation 4.6
will take the following shape:
Spindle speed (rpm) per revolution of front roller
Yarn twist (tpm) =
Delivery speed (m/min )
Or
Spindle speed (rpm) per revolution of front roller
Yarn twist (tpi) =
Delivery speed (inches/min)
Twisting mechanism 93
25,000
=
25 × 39.34
= 25.42 (m/min); working at 25 tpi
25,000
=
32 × 39.34
= 19.86 (m/min); working at 32 tpi
Thus, front roller speed need to be reduced for working with higher twist
level.
100
Or TPM = T.M. × [Eq. 4.7]
Tex
Amount of twist employed also gets changed with the change in fiber
length along with end use of yarn (Table 4.3). The following thumb rule is
employed for calculating warp and weft TM values for known fiber staple
length.
Table 4.3: Twist Multipliers used for different fiber length and yarn end use
Thumb rule: ‘T.M. employed for warp is 4.5 and weft is 4.0, with fiber
having 7/8 inch staple. With every ± 1/16 inch change in length, T.M. gets
changed by ±0.05’.
Similarly twist required for maximum attainable yarn strength for known
fiber staple length (S.L.) of fiber can be calculated by the relationship given
below:
4.25
T.M.maxstrength = [Eq. 4.9]
3
S.L.2
Yarn count spun: The yarn strengths (F) are proportional to the inclination
(helix) angles of the constituent fibers. Hence twist multiplier represents
tangent of this helix angle and for the acute helix angle its value varies in
direct relationship to yarn twist level. However, amount of twist (TPI / TPM)
is affected by yarn count and T.M. as mentioned in previous section. So, two
different fineness yarns with the same strength and twist multiplier must not
possess same twist per unit length. It is going to be more for the finer yarn as
compared to the coarser one. This can be explained with an example.
Twisting mechanism 95
Example: Two yarns A= 25s Ne and B = 64s Ne are spun with constant
T.M. of 4 to get identical strength. Then, according to Equation 4.9:
TPIA = 4 × 25 = 20
and TPIB = 4 × 64 = 32
Yarn count becomes coarser with twist contraction. Thereby yarn count
on bobbin is always coarser than the count at front roller. The mathematical
relationship between them can be given by following equation:
% TC
Yarn count at bobbin = Yarn count at front roller × 1 − [Eq. 4.10]
100
– for indiryect yarn numbering system.
Or
% TC
Yarn count at bobbin = Yarn count at front roller × 1 + [Eq. 4.11]
100
- for direct yarn numbering system.
Twist contraction (T.C.) refers the reduction in fiber strand (drafted ribbon
here) on twisting. Its value is dependent on amount of twist employed. It is
higher for higher the twist employed as per the following relationship.
Twist contraction (%) = (2.64 × T.M.) – 4.28 [Eq. 4.12]
Desired yarn characteristics: Yarn spun with low twist execute soft and
docile feel as compared to harsher feel obtained with high twisted yarn. Bulk
of the low twisted yarn is higher due to its loose voluminous structure. Fabric
produced out of such yarns gives better cover and extensibility; normally
preferred as knit yarn and weft yarn in woven structure. Thus amount of twist
used for the yarn formation is also influenced by the end product characteristics.
Table 4.3 gives an account for twist multiplier used for different fiber lengths
as per end use.
4.5 References
1. Carl A. Lawrence (2003). ‘Fundamentals of Spun Yarn Technology’, CRC
Publications.
2. De Barr and Catling H. (1965). ‘Manual of Cotton Spinning: The Principles and
Theory of Ring Spinning,’ Manchester, The Textile Institute.
3. Eric Oxtoby (1987). ‘Spun Yarn Technology’, Butterworths & Co. Ltd., London.
96 Engineering techniques of ring spinning
4. Gilbert R. Merrill (1959). ‘Cotton Ring Spinning’, Mass, Gilbert R. Merrill, Library
of Congress catalogue card number: 59-10906.
5. Klein W. (1987). ‘The Manual of Textile technology: Vol. I –The Technology of Short
Staple Spinning’, Manchester, The Textile Institute.
6. Lord P.R. (2003). ‘Hand Book of Yarn Production: Science, Technology and
Economics’, Tailor and Francis.
7. Lorenz R.R.C. (1987). ‘Yarn Twisting’, Textile Progress, Vol. 16, Number ½, The
Textile Institute, Manchester.
8. Pattabhiram T. K. (1997). “Essential Elements of Practical Cotton Spinning” Somaiya
Publications Pvt. Ltd. Mumbai, New Delhi. Fourth Edition.
9. Staldar H. (1992). ‘A new ring and traveller system as the key to more production
from the ring spinning machine’, Indian Journal of Fiber and Textile Research, Vol.
17, pp. 209–214.
10. http://www.rieter.com/cz/rikipedia/.../twist-insertion-and-yarn-formation, ‘Twist
insertion and yarn formation - Rieter’ [Accessed on 12 July 2014].
11. http://www.nptel.ac.in/courses/116102038/23, ‘NPTEL Phase II: Textile Engineering
- Yarn Manufacture - II, [Accessed on 1August 2014].
12. http://www.bracker.ch/products/spinning-rings [Accessed on 1 July 2014].
13. Winterbottom J. (1907), ‘Cotton Spinning Calculations and Yarn Costs’, Longmans,
Green and Co., London.
5
Balloon theory
5.1 Introduction
The fiber strand on emerging from front roller nip gets twisted by upright twist
mechanism as explained in the previous chapter. Turns of twist are generated
by a traveller racing on the periphery of the ring. Unsupported length of yarn
between lappet guide and traveller forced outward to form balloon. The bulge
of spherical configuration attained by yarn is controlled by traveller mass,
acting as a tensioner during spinning (Fig. 5.1(i)). Thus a finite balloon can
be formed only when there is some mechanism for maintaining a tension in
the yarn. The balloon so formed during spinning (twisting) behaves similar to
the string vibrating under adequate tension. So, the same theory can be used to
understand behavior of the whirling fibrous strand during spinning. This is used
for identifying permissible process parameters values in spinning section.
1 To
Wavelength λ = [Eq. 5.1]
f m
and
radians
Angular velocity of string ω = 2πf [Eq. 5.2]
sec
1 2π
Substituting
= to Eq.5.1, it will take the shape as
f ω
2π To
Wave length λ = [Eq. 5.3]
w m
Where, λ = Wave length in cm,
To = Tension in dynes,
f = Frequency in cycles/sec and
m = mass/unit length in g/cm.
ω = Angular velocity in radians/sec
1 981T
Where, P =
104.7n N × 10−5
T
\ P = 94.6 2
[Eq. 5.10]
Nn
The height of the balloon (H) must be kept smaller than the length of a
single node (l). Otherwise the rotating yarn interfere the bobbin enhoused
within the balloon, at the point of crossover and results in balloon collapse,
spinning becomes impossible. Thereby balloon height always kept less by
minimum admissible allowance ‘a’ from the length of node (Fig. 5.1 (iii)).
The basic condition for stable spinning in terms of balloon height (H) with
respect to length of node (l) can be given as:
H = 1 + a [Eq. 5.11]
λ
Or H = +a [Eq. 5.12]
2
Balloon theory 101
ii. Use of longer lift package along with Anti-Balloon Control (ABC)
ring. This will divide single balloon into two equal halves. Thus
resultant height of the balloon is H/2 instead of H (Fig. 5.1(iv)).
Being smaller in height, comfortably meets the condition H < ∏P and
spinning can be continued without causing balloon collapse. Apart
from that use of longer lift package born higher yarn content and
require less doffing frequency, auto doffing is not needed. However,
product yarn quality suffers from disadvantage of hairiness due to
added rubbing with ABC ring.
5.6 References
1. Eric Oxtoby (1987). ‘Spun Yarn Technology’, Butterworths & Co. Ltd., London.
2. http://www.nptel.ac.in/courses/116102038/23, ‘NPTEL Phase II: Textile Engineering
- Yarn Manufacture - II, [Accessed on 1 August 2014].
3. Ratnam T.V., Chellamani K.P. (1999). ‘Quality Control in Spinning’, The South
Indian Textile Research Association, Coimbatore.
6
Winding mechanism
Abstract: Winding mechanism lays the yarn on a tapered bobbin by bobbin lead
concept. Traveller in this course acts not only as yarn guide but also a tensioner.
However, interrelated twisting and winding mechanism of ring spinning system
brings about twist variation in yarn due to difference in traveller lag at tip and
base of the bobbin. No doubt they are not significant in their amplitude.
Key words: Winding, delivery speed, traveller lag, tape drive, tangential belt
drive, group drive, individual spindle drive, tape slippage, tape thickness, critical
difference
6.1 Introduction
Winding mechanism deals with the winding of spun yarn. Winding demands
rotating bobbin for winding the product yarn along with yarn guide to lay
yarn on its surface. According to basic winding theory, this exercise can be
performed by using either bobbin lead or guide lead concepts. All the ring
frames are operating with bobbin lead concept for winding. Thus, the main
elements of this section are bobbin (cop), spindle (driver to the cop) and
traveller (yarn guide). Since cop is the invariable part of builder mechanism
also, its features are accommodated in that section. Similarly traveller is also
involved in twisting mechanism, so its details are incorporated there.
6.2 Spindle
Spindle is a shaft for a bobbin with a predefined short length, rotating around
its own lengthwise axis. The spindle firmly supports and drives the bobbin
mounted on it. Rotations of bobbin facilitate winding of yarn delivered by
front roller. The winding is the result of the traveller lagging behind the
bobbin just enough to wrap the delivered yarn around the bobbin. Tension
developed in the yarn on winding thence after drives the traveller resting
freely on it, parallel to spindle. Thus traveller lags behind the spindle speed
by winding revolutions. These rotations of traveller insert the turns of twist to
the drafted strand emerging out of the front roller. Thus spindle performs two
Winding mechanism 105
basic functions of spinning, viz. twisting and winding. However, both of them
demands assistance from the traveller.
(II) Bearing housing: It is the bottom end and the stationary fixed element
of the spindle. It is the lubricating arrangement for the highest speed driven
part of the machine. Thus it is an antifriction device for central shaft of the
spindle. Normally regarded as bolster and fitted in the holes bored in spindle
rail for it. Bolsters are broadly classified in two categories based on its
structural variations;
(i) Regular plain bearing bolster: It is used on conventional slow speed
frame. It is provided with upper sleeve bearing (neck bearing) and simple
hollow cast iron 100–140 mm long and average 10 mm outside diameter
tube. Tube is filled with antifriction oil, circulating through the bolster for
lubrication center shaft blade (Fig. 6.1 (iii)). Bolster is constructed with one
or more vertical slots or grooves in the outside of the top end of the tube.
These slots permits the oil raised up wards due to capillary action to flow
down back into the base for recirculation. Under normal running conditions,
the temperature of the oil in the bolster is 10 to 12 degree Fahrenheit above
the room temperature. If it exceeds beyond 20 degree F, indicates mechanical
trouble. Hence this system does not permit spindle to operate beyond 8000
rpm. So, it is obsolete on modern high speed ring frames.
(ii) Anti-friction bolster: It is the one which is used on modern ring
frame. The antifriction spindle bearing consists of compound of bearings; a
spindle collar bearing and a spindle step bearing. Both parts are connected via
housing. The housing carries oil tube, oil level control and damping device
apart from these bearings (Fig. 6.1 (vi)).
The spindle collar bearing: It comprises a precision roller bearing. The
spindle collar can be a friction bearing or a roller/needle bearing. The noise
level can be reduced considerably by using friction bearings, but energy
consumption is somewhat higher. Most spindles are therefore equipped with
roller /needle bearings.
The spindle collar wharve is rigidly friction-set in the bearing housing
in standard spindles. Bearing vibration is therefore transmitted to the spindle
frame without damping. This results in high noise levels at higher speeds. For
speeds over 18,000 rpm, spindles are therefore mostly used in which not only
the spindle step, but also the spindle collar is attached flexibly to the bearing
housing. These spindles are more expensive, but permit higher speeds and
reduce noise levels in ring spinning machines by some 10 dB compared with
standard spindles. The bearing is often referred as neck bearing as it holds the
spindle in proper lateral upright position and supports the pull of the driving
media (tape/band) used to drive the spindle.
The spindle step bearing: It is a steel-inverted conical step to just fit
the lower tip end of the spindle. According to its shape it is designed as a
108 Engineering techniques of ring spinning
conical bearing (friction bearing), and responsible for the elastic centering
and cushioning of the spindle center shaft. An oil-filled spiral mounted
symmetrically with the spindle step ensures optimum cushioning to blade as
well as bolster. Spindle step bearing surfaces carries the weight of the spindle,
bobbin and yarn. It also absorbs all vertical forces acting on the spindle.
The inside diameter of the central part of the bolster is considerably larger
than the blade diameter, leaving enough room for a reservoir of oil. Whereas
outside portion of the bolster is turned to the dimension to fit well within
spindle bore, perfectly in a vertical position. It is also provided with threads
and fixer nut to secure firmly in vertical position on spindle rail. The mounting
of spindle on the spindle rail is called “spindle plumbing”. The accuracy of
plumbing is checked with the help of spindle gauge (Fig. 4.1 (i)). Spindle step
is always a friction bearing and flexible, i.e. it can tilt sideways to a small
extent. The spindle is therefore able to center itself, which enables it to operate
in hypercritical ranges. This results in a significant reduction in bearing forces.
High-performance spindles are inconceivable without damping devices.
Various systems are used, such as damping spirals, damping tubes or damping
oil around a steel tube. If damping spirals (viscous dampers) are used, spiral
spring is compressed at one side when the spindle is deflected to side (Fig. 6.1
(vii)). The oil therefore flows from this side to the other side, where the gaps
become wider. The resistance the oil has to overcome in the process damps the
vibration in the spindle step and ultimately in the shaft. The cavity between
the spindle blade and the bearing housing is largely filled with lubricating oil.
Since the oil is used up, it has to be replenished from time to time. This is
necessary after about 10,000–25,000 operating hours.
(i) Tape drive: Fabric tapes are used for driving spindle or spindles in a
group. Conventional ring frame tapes were made up of woven cotton fabric
produced with herringbone or grosgrain weave. They were having 12–20 mm
width and 1.27 mm thickness. Tape ends were overlapped and sewn together
with 2–3 lines of backstitch on regular lockstitch machine. This stitch joint
adds to the thickness. Hard joint continuously knocks with wharves and
thereby off set spindles faster. Even its weight per running yard (meter) was
also high. Such heavier tapes increases power consumption and wear.
Modern ring frame tapes are thereby made up of light but stronger
manmade textile material, mainly nylon. They are spun bonded nonwoven
fabric. Tape ends are fused together or tapered adhesive bonded. Such joint
offers not only reduced joint thickness and hardness but saves spindle setting
for a long duration due to reduced intensity of spindle knocking. There are
two types of tape drive in use: (a) group drive and (b) individual spindle drive.
Group drive or four-spindle tape drive: Single tape drives two spindles
on one side of the machine and two further spindles on the other side of the
machine in a group of four. When changing from one side to the other the
tape passes around a drive cylinder (tin roller – old system) or Bakelite drive
pulley (new system) and 1–2 tension rollers (jockey pulleys). Dead weight
or spring loaded jockey pulleys ensure good, uniform tensioning of the tape
(Fig. 6.2 (i)). The power is transmitted to tin roller or pulley shaft via flat or
V-belt from main shaft. Use of lightweight tape and Bakelite pulley offers
less frictional resistance to drive. Thereby force required to drive low mass
frictional bodies is less, consumes less power, and makes drive economical.
110 Engineering techniques of ring spinning
Less driving force also reduces tape tension or contact pressure for accurate
drive transmission. Thereby pulley and tape wear get reduced, adds to their
life and also allows working at low noise level. The greater angle of wrap
(110° to 120°) around the smaller diameter wharve guarantees constant
rotation speeds by significantly avoiding tape slippage. This results in
reduced count and twist variations, thus produces better yarn quality. If tape
breaks or need to be replaced, only four spindles are out of production, helps
in realizing higher machine efficiency.
Although, the system has undergone lot of changes to meet with the
requirements of high speed operation of ring frame, it suffers from some
major draw backs:
i. Only one count is spun on the entire ring frame due to common driver
for both the sides of the spindles.
ii. Length of the tape required is 2 m to 2.2 m. Thus long unsupported
length of the tape involved in this drive results in fluttering at high
speed. Even whirling up of fly takes place.
iii. Thin tape, although made up of stronger nylon sandwich material has
shorter life span.
iv. Joint formed to get endless belt gives periodic variations. Even
continuous knocking of this hard and thicker joint with spindle wharve
has a tendency to move the spindle out of center and consequently
need repositioning from time to time.
v. Area below roller beam is occupied by driving elements, demands
extra lighting for maintenance.
vi. Bakelite pulley diameter is normally ranges between 200 mm and
230 mm. Wharve diameter can be reduced maximum to 18 mm, not
beyond that due to limitations of neck bearing size. These will not
permit increase in spindle speed practically beyond 25,000 rpm.
Continuous attempts have been made to overcome these limitations. The
outcomes of these sequences of efforts have been briefly summarized below
along with their associated advantages and disadvantages.
Direct drive to the spindle: All the limitations associated with the tape
drive originated from the longer length of tape utilized in the drive and its
control at high speed drive. Direct drive to the spindle is the option though off,
to overcome these limitations. Two modes of individual spindle drive have
been designed for the purpose:
i. Mechanical or Individual spindle tape drive (Fig. 6.3 (ii)) and
ii. Motorized direct drive (Fig. 6.3 (iii)).
directly the spindle mounted on its axis. Thus problematic tapes are eliminated
fully. Even there is no need of any driving accessories like pulley, shaft, jockey
pulley, tension adjuster, etc. Clean and clear space is available below the roller
beam provides ease to maintenance and setting. All the motors are working in
synchronization with front roller motors via inverter control. This set up helps
in varying twist with the fingertip control.
Here each spindle operates individually, so deals with different count
simultaneously. At the moment of break down or maintenance only one
spindle remains out of production. However, the initial cost of the system
and power consumption is high for this conceptionally attractive system. So,
in commercial short staple spinning systems only group drive in the form
of 4-spindle tape drive or tangential belt drive is usually used.
1. Tape slippage
2. Tape thickness
3. Traveller lag and
4. Twist contraction
(1) Tape slippage: The most preferable of spindle drive is tape drive due
to its higher accuracy owned by higher angle of wrap (110–120) as mentioned
in earlier section. But frictional mode of drive introduces slippage of the
order of 3%. Thereby twist inserted to the spun yarn is accordingly less than
theoretically calculated and set with twist gearing.
(2) Tape thickness: Twist calculation involves only driving gear ratio
between front roller and spindle. But tape thickness value is ignored being
thinner. This differs theoretically calculated one from actually inserted in yarn
by 4–5%. This can be well elaborated with an example.
Example: Spindle driving pulley speed is 1,000 rpm and its diameter
is 200 mm. Tape of 1.6 mm thickness is used for driving wharve of 25 mm
diameter.
Theoretical spindle speed (by neglecting tape thickness)
200 ×1 000
= = 8,000 rpm.
25
But
Actually attainable spindle speed (by considering tape thickness)
201.6 ×1 000
= = 7,579 rpm.
26.6
The percent critical difference between actual and theoretical speed is five
percent. Thus actually attainable spindle speed is five percent less in practice
due to tape thickness.
(3) Traveller lag: Traveller due to its own mass and friction with the ring,
resists motion and can be pulled around only when the yarn between the front
roller and bobbin is tight enough (i.e. winding is done). Thus traveller speed
is always less than the spindle speed by winding revolutions. This short fall
in traveller speed is known as traveller lag. Since winding revolutions are
defining traveller lag, it purely depends on diameter of the bobbin for constant
delivery speed of ring frame.
This can be explained with above mentioned example only. Assume a
spindle speed of 18,000 rpm, the bobbin diameters of 46 mm at the base and
25 mm at the tip, and a delivery of 25 m/min, the traveller speed at the tip (Ntt)
will be,
Winding mechanism 117
6.4 References
1. Carl A. Lawrence (2003). ‘Fundamentals of Spun Yarn Technology’, CRC
Publications.
2. De Barr and Catling H. (1965). ‘Manual of Cotton Spinning: The Principles and
Theory of Ring Spinning,’ Manchester, The Textile Institute.
3. Eric Oxtoby (1987). ‘Spun Yarn Technology’, Butterworths & Co. Ltd., London.
4. Gilbert R. Merrill (1959). ‘Cotton Ring Spinning’, Mass, Gilbert R. Merrill, Library
of Congress catalogue card number: 59-10906.
5. Klein W. (1987). ‘The Manual of Textile technology: Vol. I –The Technology of Short
Staple Spinning’, Manchester, The Textile Institute.
6. Lord P.R. (2003). ‘Hand Book of Yarn Production: Science, Technology and
Economics’, Tailor and Francis.
7. Lorenz R.R.C. (1987). ‘Yarn Twisting’, Textile Progress, Vol. 16, Number ½, The
Textile Institute, Manchester.
8. Pattabhiram T. K. (1997). “Essential Elements of Practical Cotton Spinning” Somaiya
Publications Pvt. Ltd. Mumbai, New Delhi. Fourth Edition.
9. http://www.rieter.com/.../ring-spinning/...spindle/...spindle.../4-spindle-tape-drive,
[Accessed on 12 July 2014].
10. http://www.rieter.com/en/.../ring-spinning/...of...spindle/the-spindle-bearing
[Accessed on 12 July 2014].
11. http://www.rieter.com/cn/.../ring-spinning/structural...spindle/spindle-structure,
[Accessed on 12 July 2014].
12. http://www.nptel.ac.in/courses/116102038/23, ‘NPTEL Phase II: Textile Engineering
- Yarn Manufacture - II, [Accessed on 1August 2014].
7
Builder mechanism
Abstract: The ring spun yarn is wound on the spindle-driven cop in association
with traveller, acting as a guide and tensioner. Traveller receives angular
movement on ring via yarn tension and simultaneously linear movement from
ring rail. Thus bobbin building and winding both the mechanisms are going
together. Builder motion has to lay yarn on the entire length of package in a
peculiar pattern. Three types of building patterns are used in the production
course, viz. warp wind, weft wind and assembly wind. Except few exceptional,
majority of the ring frames follow weft wind pattern only. So, the present chapter
is restricted to these ongoing practices only.
Key words: Bobbin, cop, builder mechanism, weft wind, layering traverse,
switching traverse, cop heel, shoulder heel, under winding, back winding, reserve
coil, builder cam, ring rail, ABC-ring, lappet guide, damping cylinder, servo grip
7.1 Introduction
Previous chapter has given an account for winding mechanism. The ring spun
yarn is wound on the spindle-driven cop in association with traveller, acting
as a guide and tensioner. Traveller receives angular movement on ring via
yarn tension and simultaneously linear movement from ring rail. Thus bobbin
building and winding both the mechanisms are going together. Traveller
is mounted on ring carried by ring rail. This ring rail has given continuous
layering traverse and switching traverse to lay yarn on the entire length of
package in a peculiar pattern. The pattern observed for laying the yarn on the
cop (bobbin) is referred as bobbin building. Three types of building patterns
are used in the production course, viz. warp wind, weft wind and assembly
wind. Except few exceptional, majority of the ring frames follow weft wind
pattern only. So, the present chapter is restricted to these ongoing practices
only.
180 mm and 260 mm. More the height of the bobbin, the more yarn can be
accommodated on it, allows ring frame to work with reduced doffing frequency.
Some height, 10 mm at the top as well as bottom, remains uncovered by yarn
during bobbin build up. The height used for winding the yarn is known as lift
of the bobbin (LG). Bobbin is also slightly tapered at the top with the taper
angle 1:38 to 1:64. The inside dimensions of the tube are made to make it
perfectly fit on the spinning spindle. Tubes are stable and rigid enough. They
are designed for the particular set of spindles and thereby cannot be used on
spindles of different size or design. The outer surface of the tube is used for
winding the spun yarn without undue slippage, thereby it is provided with
engraved lines.
tapes. This results in the slow upward displacement of the ring rail for laying
winding coils. The short steep portion of cam causes downward movement of
ring rail via the same channel but the operating force is generated by the weight
of the ring rail assembly. This downward movement of the ring rail is thereby
rapid but with decreasing speed. Fast downward displacement of the ring rail
is responsible for laying binding coils. Thus builder arm is continuously raised
and lowered with the tape pulley due to the rotation of the cam and mass of ring
rail assembly. The cam is driven positively from the main drive via lay gearing.
The gearing responsible for laying yarn coils on the bobbin is referred as lay
gearing. The up and down movement of doffing lever transmitted to the ring rail
via pulleys and the tapes is known as layering traverse.
ring rail has given a continuous ascent in very small amounts after each
layering traverse in order to fill the entire cop, referred as switching traverse
or advancement. This movement should not interrupt operating of layering
traverse but works in a synchronization with it.
Again an account is given to LMW G5/1 Ring frame for explaining
operational mode of switching traverse. It consists of a worm wheel on the
builder cam shaft, receives the drive from the mains gearing (Fig. 7.3). It
carries on its back side 1–3 driver pins fitted in the slot and at equidistance.
The mounting of number of pins depends on the rate of advancement desire.
Higher the number of pins on worm wheel, faster the advancement and so on.
Rotation of the wheel during layering traverse also rotates the pin/s around
the shaft. This movement of the pin/s makes the sector loosely suspended
behind the worm wheel to be raised along. Upward ascent of the sector moves
small pinion in its meshing to rotate anticlockwise. Pawl lever fashioned on
the pinion shaft gets the similar angular displacement and makes the catch
to turn the advancement ratchet wheel in an anticlockwise direction. This
small turn of ratchet wheel is given to tape drum connected to the ratchet
wheel via gearing. The movement is such that the tape gets wound in a small
amount onto the drum. Thus, shortens the tape length available between tape
drum and guide pulley fitted on doffing lever. This increases tape tension
and enforces set of pulleys, tapes, cam and shaft to rotate for compensating
shorten length and results in a slight rising of ring rail. This upward shift of the
ring rail switches next traverse to commence from the new position. Thereby
this mechanism is referred as switching traverse. The amount of upward
displacement is known as advancement. Its magnitude gets varied as per the
adjustable stroke (angular displacement) of pushing pawl and can be read off
from the advancement dial. The downward displacement of the sector is due
to its own weight and that will make the catch to slip past the ratchet wheel
teeth.
angular displacement (θ = s/r) for pulleys, connected via tapes. However, the
cam attached to the pulley before the cross shaft, projects over the periphery
of pulley, adds to the working radius (r) of the pulley by its length (l). As a
result of this when winding on the empty cop commences, cam deflects tape to
some more degree, as shown in Fig. 7.3. Thereby angular displacement earn
by the next pulley (mounted on cross shaft), in sequence is less than actually
transferred by the cam in normal course, viz. θ(cop heel) = s/(r + l) instead of
θ = s/r. Because, part of the linear displacement (s) of the tape arising from the
rise of doffing lever is not passed on to the ring rail, but get lost as deflection
at cam. The ring rail traverse no longer corresponds to the specification, it
becomes smaller. The heart-shaped cam (builder cam) and the delivery roller
are coupled together by the drive gearing. Thus, the length of yarn delivered
for each revolution of the cam is always the same. Since the yarn delivery
length per traverse remains unchanged, the bulk (yarn coils) per layer wound
on the bobbin is increased. This result in the more densely populated cop base
having convex shape instead of flat tapered one.
The position and design of the cam is selected such that the height of the
layer increases gradually, till it moves totally away from getting in contact
with the tape. This is attained by winding of the tape on the take up drum for
each double layer formation (layering traverse). The tape winding drum is
turned continuously to the left after each layering traverse in small amounts
by the winding ratchet wheel of switching traverse mechanism in the further
course of spinning (Fig. 7.3). Winding of the tape on take up drum makes
pulleys involved in the drive, to turns in the right in equally small amounts.
This moves cam (segment) away from the working region of the tape and
thereby, the cam is increasingly less engaged. The rounded surface of pulley
now offers smaller working radius (r) to the tape. So for the given constant
linear displacement (s) of builder cam, angular displacement (θ) earn by the
pulley on cross shaft becomes more. Once this stage is reached, the heights
of the further layers do not change till the end. Thus after base formation the
entire movement of the tape is passed on to the ring rail and the cop builds up
normally.
The base of cop formed is spherical convex instead of flat tapered one.
This cop base build up phenomenon is explained in Fig. 7.4 (i–iii). The
volumes of the individual double layers are equal for the constant delivery
128 Engineering techniques of ring spinning
rate of the frame. Hence tapered bobbin is used, deposition of double layers on
the tube begins with a small average layer diameter d1. The average diameter
increases gradually with each newly deposited layer from d1 to dn. During cop
heel formation winding is carried out with constant layer volume but with
increasing height of the layers as explained above. Thus in the beginning of
the doff, the layer width goes on reducing from b1 to b2 to b3, and so on till
the height reaches fixed level (cop heel formation ends). Since the ring rail is
also raised by a constant amount ‘h’ after each deposited layer, by switching
traverse. The base shape resumes the curve, rather than straight line. Thus
convex shape arises automatically in the base portion.
Conical layers instead of cylindrical layers are formed throughout the cop
building. The non-uniform movement of the ring rail results in the formation
of the conical layers. Hence ring rail speed increases during upward movement
and falls during downward movement. As a result of this at the tip of each
layer winding tension is higher than at the base of the layer. Because the ring
rail does not dwell as long at the tip, as it does at the base. So, less material
gets wound at the tip makes the layer thinner at the tip (Fig. 7.1 (iii)). Cop
build up is mainly influenced by this non uniform movement of the ring rail
and well explained with a numerical figure (Fig. 7.4 (iii)).
If the ring rail is assumed to be moving twice as fast at the top of its
strokes as at the bottom of the stroke, the first layer would be half as thick at
the top as at the bottom, i.e. b1/2 instead b1. The first layer would correspond
to a trapezium with the side b1 at the bottom and the side b1/2 at the top. This
is followed by the deposition of the second layer. Owing to the lifting of the
ring rail, the upper portion of the new layer would again be deposited on the
bare tube. The average diameter at the top would be the same as that of the
first layer, and the volume, and hence the thickness, would also be the same,
that is b1/2. Each newly deposited layer will have this thickness of b1/2 at the
top. At the bottom, however, the diameter is increasing continually, the layer
thicknesses decline from b1 to b2 to b3 to b4…as explained above. Accordingly,
continually narrowing trapezium are produced. At some stage, the trapezium
will become a parallelogram, i.e. the lower side will be the same size as the
upper side: both will be b1/2. Since all other winding conditions now remain
the same, no further variation can now arise in the layering. One conical layer
will be laid upon the other until the cop if full, that is when the cylindrical
portion of the cop is formed.
of tapered one in order to increase yarn content of the bobbin. The building
concept is same as that of cop heel formation, use of segment, cog or projection
to vary the angular displacement of the pulley and thereby traverse length.
However, high speed unwinding of such cops on the winder significantly
rises sloughing off tendency. This is totally an undesirable condition for
productivity of the next machine in sequence. So, now-a-days with high speed
winder shoulder heel formation mechanism has not found place on high speed
ring frames.
The gear train transfers drive to the builder cam from the front delivery
roller is known as lay gearing. It defines the cam speed in relation to the
front roller delivery speed. Thus coil density on bobbin for ring rail double
traverse gets affected by the size of lay gear. If lay gear with too many teeth
are inserted, cam moves fast and the final condition of constant conical layers
will be reached too soon and the cop tip will be too thin. Similarly it will be
too thick if the ring rail is lifted too slowly. Thus shape of the cop tip is mainly
influenced by the size of lay gear.
ring rail position fixed and performing advancement via spindle rail
can help in keeping balloon height constant, major contributor to
yarn tension. Thus it facilitates in reducing within bobbin variations
due to spinning tension change during cop build up. However, the
system not found commercial success due to complications involved
in practical implementation of theoretically fascinating mechanism.
The difficulties were observed in retaining constant belt and tape
tension used in spindle drive. Consistency in spindle drive was lost
due to increased slippage. The system was not found beneficial
although started with logical thought of controlling root cause for
within bobbin variations. Nowadays all modern machines operate
exclusively with a moving ring rail. But influenced by Reiter’s way
back thinking, they all are equipped with auxiliary mechanisms for
controlling working balloon height almost constant.
Ring rail as on today, performs two types of movements throughout the
cop build up:
• Continuous traversing and
• Shifting upward by constant amount after each double traverse.
Both the movements of the ring rail have an adverse influence on spinning
tension. In particular, the size of the balloon and the winding diameter on
the cop are never the same. Their relationship with spinning yarn tension is
well explained in earlier sections. Tension variations caused due to change
in winding diameter are totally unavoidable. As they are attributed to the
tapered shape of the bobbin and cop build up pattern adopted during winding.
On the other end, balloon diameter is always controlled by using practically
optimized traveller mass in order to avoid balloon collapse or balloon slashing.
So, balloon height is the only left behind variable, need to be controlled.
However, its value is continuously changing with each coil and layer winding.
Efforts must be made to maintain balloon height almost constant throughout
spinning in order to control spinning tension variations.
Anti-Balloon Control (ABC) Ring is designed to divide single balloon
into two equal sizes and thereby reducing spinning tension, as mentioned
earlier. It is therefore kept right at the middle position to that of thread guide
eyelets and ring rail, between which balloon forms. If balloon control rings and
thread guide eyelets are kept at fixed positions for moving ring rail throughout
bobbin build up, the balloon height will change continuously according to
the change in ring rail position. These results in within bobbin yarn tension
variations. Balloon control rings and thread guide eyelets have also been given
traversing and advancement in synchronization with ring rail, via the same
operating mechanism to avoid larger fluctuations in balloon height. However
Builder mechanism 131
their movements are albeit by smaller amounts in both layering and switching
traverse (Fig. 7.3). Hence the magnitude of movements is restricted by the
spinning geometry.
The mechanism includes different traversing and advancement strokes for
all the three parts moving in synchronization. So, the driving mechanism up
to driver shaft (Cross shaft) is common for all the components (Figs. 7.2–7.3).
But balloon control ring rail and thread guide eyelets board are suspended
on proportionately smaller diameter driven stepped pulleys via tapes. The
cam pulley transfers the drive to driven pulley on cross shaft. This pulley
is compounded with driver pulleys of ring rail, lappet guide and ABC-ring.
So, they are also raised and lowered along with ring rail in synchronization.
However, steps (diameters) of driver pulleys for ABC-ring (DABC) and lappet
guide (DLG) are rather smaller than driver pulley for ring rail (DRR). That is
DRR > DLG > DABC. Thus for the constant angular displacement (θ) received
by the cross-shaft, the traverse motion attained by respective components is
accordingly smaller.
thereby designed to preserve threading and eliminate all such delay. Simply
by placing empty bobbin and bringing ring rail, lappet guide and balloon
control ring up to the starting position. Thus, next doff can be started within
few seconds to doffing. This reduces undue down time of the ring frame and
enhances its efficiency.
Apart from this, it also helps the operator on winder or next machine in
sequence to locate the yarn end easily due to back winding. This can save time
and increase efficiency of the next machine also. Back winding (Fig. 7.5 (i))
refers winding of the yarn from the tip of the bobbin to its base during ring rail
reversal for the under winding.
near about the base of the bobbin, thereby ring rail which born yarn
guides for winding (travellers), is reversed and also dropped below
the starting position.
iii. Under winding: Only 4–5 coils to be laid loosely at the base of
the bobbin for the purpose. Half the rotation of the driving wheel
is enough to perform this job for its approx., 10:1 ratio with driven
wharve diameter. Thereby once the ring rail gets reversed; there is
no need to drive the spindle later on. So, the power supply of the
motor should cut off immediately once ring rail occupies the under
winding position. Hence spindles are driven at high speed (25,000
rpm), residual rotations of driver wheels are quite high enough before
resuming steady state condition on switching off the power supply.
Brake must be applied along with switching off the power supply to
the main shaft of the machine. This brings driving wheel to steady
state condition within half of its revolution. This is enough to lay
reserve coil bunch, otherwise increases hard waste unnecessarily by
laying more number of coils.
ratchet wheel and thereby rotates tape wind up drum in anticlockwise direction
throughout the cop build up. This shortens the tape length between builder
arm pulley and guide pulley. These anticlockwise turns are also earned by
under winding cam, mounted on take up drum shaft. It is fastened in such a
way that its stroke (larger throw) is off set from the sensor switch b26, in the
beginning of doff. Angular distance between larger cam stroke and switch
is set according to time required for complete cop building before initiating
under winding. It is mainly affected by yarn count, as rate of bobbin diameter
build up varies with yarn count. Wider difference is kept for finer count owing
to its slower build up rate and vice versa.
Two basic conditions must be fulfilled to start with under winding. They
are:
i. Ring rail and anti-balloon rings must occupy under winding position.
ii. Simultaneously lappet guide must resume top most position as well
as get tilted for the ease of doffing.
They are achieved by unlocking the respective parts from their normal
working position by releasing related limit switch (here, b26) on the completion
of cop winding. Also signal must be send to actuate various limit switches
(bxx), contactors with timers (delay switches, dxx) and electromagnetic solenoid
valves (sxx) operated pneumatic pistons (pxx) to accomplish under winding as
per the scheduled operating sequence.
movement in the lower third of the cop. The pipe with stop cock is
provided for the purpose on the damping cylinder (Fig. 7.8).
Cut off the drive and laying under winding coils: Switch b40 on
5.
getting energized also sends a signal to actuate relay d27. However, it
gets actuated 1–20 seconds after receiving the signal. Its function is
to stop the main motor and fan motor, and also actuate brake. Cutting
off main drive along with application of brake can bring machine
instantaneously to the steady state but after the set delay. Duration
of delay purely depends upon the yarn count, twist and number of
under winding coils desire. Hence front roller speed is low for higher
twist. So, for the given number of under winding coils, timer of delay
is kept more. Similarly for finer count front roller speed is more, so
duration of delay is short. Thus it gives an enough time to the front
roller for delivering yarn length required to wind desired number of
under winding coils before declutching main drive. According to set
delay time spindles also continue rotations to build up require under
138 Engineering techniques of ring spinning
Restoring position of ring rail: The moment switch b26 is pressed and
6.
connected to relay switch b40, the same time it also gets connected
with relay d23. But it gets actuated after time lag of 1–5 seconds
from the point of receiving signal. The function of the relay d23 is to
re-engage the clutch by turning off solenoid S7 and timer d27 for the
next doff and restore ring rail back to the starting position (Fig. 7.8).
Long snarl removal: Ring rail after under winding moves back to
7.
the starting position. This makes yarn between front roller nip and
ring-traveller slack. In addition to this restarting of the motor operates
140 Engineering techniques of ring spinning
spindles first but takes a time to operate font roller (approx. 4 seconds)
depending on the length of gear train involved in the drive. As a result
of this the slacken length gets over twisted by the spindle rotations
occurs before getting new delivery length from the front roller.
This over twisted length has a tendency to snarl and likely to cause
multiple end break at the beginning of doff. Piston P1 is provided to
remove this snarl by giving short upward stroke to the lappet guides
in the beginning of doff for taking up the slackness and then descend
back to the starting position during winding (Fig. 7.11).
revolving slowly at the completion of doff. The yarn gets inserted in the open
crown and the crown gets closed afterward. When the cop is replaced, the
length of the yarn remains firmly clamped by the teeth of crown, eliminating
need of piecing on restarting the machine. Even the small loop of yarn caught
by crown gets released on its reopening for the next cycle. This also eliminates
need for cutting the yarn coils as in the previous case, responsible for the fly
generation. Thus the system has offered a better solution in terms of saving
labour power, damage to the spindle on cutting and generation of hard waste
along with better housekeeping.
7.6 References
1. De Barr and Catling H. (1965). ‘Manual of Cotton Spinning: The Principles and
Theory of Ring Spinning,’ Manchester, The Textile Institute.
2. Eric Oxtoby (1987). ‘Spun Yarn Technology’, Butterworths & Co. Ltd., London.
3. Gilbert R. Merrill (1959). ‘Cotton Ring Spinning’, Mass, Gilbert R. Merrill, Library
of Congress catalogue card number: 59-10906.
4. Klein W. (1987). ‘The Manual of Textile technology: Vol. I – The Technology of Short
Staple Spinning’, Manchester, The Textile Institute.
5. http://www.nptel.ac.in/courses/116102038/23, ‘NPTEL Phase II: Textile Engineering
- Yarn Manufacture - II, [Accessed on 30 August 2014].
6. http://www.rieter.com/en/rikipedia/articles/spinning.../builder-motion, [Accessed on
30 August 2014].
8
Doffing
Abstract: Doffing deals with the replacement of cop by empty bobbin tubes to
restart with new doff. Classical ring spinning was labour intensive system and
thereby this job was performed by a team of unskilled doffer boys. However,
it was full of human error and operating with low working efficiency. Thereby
manual practice of doffing is discontinued on modern, long and high speed running
ring frames now a days. Electronically controlled robotic arms auto doffing has
replaced this labour compliment from the production course. This has assured
product quality at a much higher working efficiency, but at some additional cost.
A brief review of this entire changeover is elaborated stepwise in this chapter.
Key words: Cop, bobbin tube, doff, labour, doffer boys, efficiency, conveyor belt,
doffing rail, gripper, doffer rail
8.1 Introduction
Once the cop gets ready, it needs to be replaced by empty bobbin tubes to
restart with new doff. The entire exercise refers as doffing. Classical system
was labour intensive as many unskilled doffer boys were involved in this
exercise and machine remains production less for the time being. It was not a
good practice in terms of quality and economy of the product. So, this practice
of doffing is discontinued on long and high speed running ring frames now-
a-days. Electronically controlled robotic arms; auto doffing has replaced this
labour compliment from the production course. Thereby assured quality along
with desired productivity but at some additional cost. A brief review of this
entire changeover is elaborated stepwise in this chapter.
8.2 Doffing
Once the cop is ready it needs to be replaced by the empty one, known as
doffing. The capacity of full ring cop ranges between 30 g and 100 g of yarn,
depending on yarn count spun and size of the bobbin used. Nevertheless, it
takes 1–30 hours to fill it. Both the figures purely dependent on the type of
yarn spun. Doffing can be carried out manually (old) or mechanically (new)
after under winding is over.
144 Engineering techniques of ring spinning
7. After doffing gets completed, the doffer returns to its idle position
below the spindles. At the same time the ring rail rises to the piecing
position, the balloon checking rings move upward and the yarn guide
flaps tilt downward. The machine starts.
8. The conveyor belt moves the doffed cops toward the end of the
machine, where they are discharged into transport trolleys or
individually transferred directly to the winder. Duration of automatic
doffing can be as short as 2 minutes.
During automatic doffing, the procedure is interrupted once or twice for
inspection. Correct functioning must be repeatedly checked; in particular,
care must be taken that tubes are donned on all spindles and are not jammed.
8.7 References
1. http://www.rieter.com/.../rikipedia/.../spinning.../automation/doffing/automatic
[Accessed on 25 August 2014].
2. Klein W. (1987). ‘The Manual of Textile technology: Vol. I – The Technology of Short
Staple Spinning’, Manchester, The Textile Institute.
9
Spinning geometry
9.1 Introduction
Spinning geometry as the name suggests deals with the geometrical
measures of machine parts involved in spinning. They are defining different
angles of deflection and path lengths observed by fiber flux (yarn) during
spinning. They have a significant influence on the spinning process and
thereby final yarn quality and cost. A scientific approach is needed for
optimizing all such parameters participating in spinning geometry. This can
help in sustaining not only spinning stability but also assures yarn quality
and economy. Present chapter describes scientific relationship of various
spinning measures that may be constant or variable on the performance of
product yarn. Also their optimized values used in industrial practices as
on today are mentioned.
(Fig. 9.1), have a significant influence on the spinning process and final yarn
quality, and especially on:
• tension conditions
• ends down frequencies
• yarn irregularity
• fiber integration
• yarn hairiness
• incidence of fly
(iii) Spinning triangle: If it is too short, core fibers will be tied in without
tension. They can then absorb tensile forces in the axial direction only
to a limited extent, or only after the fibers in the outer layer have
been broken. Since the distribution of tension forces in the final yarn
is similarly uneven to that in the spinning triangle, the yarn shows
the same effect. When stress is applied to the yarn, the edge fibers
undergoes so much elongation from the very beginning that the
forces acting on them either cause the fibers to break, or in some cases
to slide apart before the loading forces can act on the neighboring
fibers inside the yarn. Fiber breaks proceed successively from outside
to inside. The yarn has low strength. Since the twist inserted in the
yarn is insufficient due to the uneven distribution of tension (the edge
fibers are ultimately wrapped around the core fibers), the negative
effect is reinforced. The yarn structure falls short of the optimum,
and most of the yarn quality parameters suffer more or less. Thus ring
spinning does not permit to work with too small triangle. Similarly
too big triangle represents longer weak band as explained above and
give rise higher end breaks.
It is therefore evident that as long as a significant spinning triangle
exists, perfect yarn structure with excellent spinning performance cannot
be achieved. It is necessary to find ways to reduce the size of the spinning
triangle drastically, and above all to reduce the width of the fiber flow exactly
to the width of the remaining spinning triangle. This has been achieved by so-
called compact spinning systems.
Length of the spinning triangle allows varying in a range between 2.5 mm
and 7 mm only but according to the machine design of different manufacturers.
(α = 60°). However, the value should not be increased beyond 60° otherwise
piecing becomes a problem.
this set of spinning geometry piecing becomes difficult. So, value of angle of
obliquity is always kept below 90 degree.
According to relationship ‘Sin γ = b/a’ (Fig. 9.3 (ii)). The angle of
obliquity is at minimum,
• If the horizontal distance between the spindle shaft and the nip of the
drafting rollers (b) is the shortest, and
• If the vertical distance between the lappet and the drafting rollers (a)
is the longest.
The diminishing of measure ‘b’ is restricted by the position of the lappet,
ring rail, separators and balloon control rings. The constructional height of
the ring frame determines the increment of dimension ‘a’, first of all from the
point of view of the easy operation of the frame. The increment of dimension
‘h’ is also governed by the constructional height of the frame, i.e. by the
particular value of maximum balloon height (Hmax). Thus, taking into account
the above aspects, the most advantageous range of angle of obliquity for yarn
guiding can be determined.
On the upward ascend of lappet guide, value of ‘a’ reduces for constant
‘b’ as per machine set up used. This makes spinning triangle smaller and
wider angle of obliquity (γ2). Accordingly normal force (N), resisting twist
flow becomes smaller, so twist propagation to the fiber strand will be better.
The highest value γmax arises at the end of cop build up, permits to work at
smaller balloon height. Smaller balloon height Hmin allow spinning to continue
at low tension and thereby at reduced end break. The favourable situation will
be continued up to 35° spinning angle. Further rise in value causes increased
end down frequency due to poor yarn strength occurs at reduced orientation
while working with low spinning tension. Apart from this lappet guide exerts
braking effect on the pulsation of the balloon, which seldom rotates smoothly.
Continuous impacts and vibrations are arising due to traveller speed variation
during layering traverse. Balloon absorbs them and not allowed end to break.
But with smaller balloon formation, almost triangular balloon, at the tip of the
bobbin, this flexibility of dampening vibration diminishes results in excessive
end breaks.
Similarly the lowest position of lappet guide arises at the beginning of cop
build up. At this position, ‘a’ increases to ‘a + h’ for constant ‘b’ as per machine
set up used. Thus makes spinning triangle longer and angle of obliquity (γ1)
smaller. As a result, normal force ‘N’, resisting twist flow increases, so twist
propagation to the fiber strand will be poor. Formation of longer spinning
triangle or weak band along with higher spinning tension owing to bigger
balloon height accelerates end down frequency (Fig. 9.3 (i)). The favourable
spinning situation arises up to 15° spinning angle formed for the lower most
Spinning geometry 157
position of lappet guide. Going beyond this value spinning stability is not
achieved.
The distances measured from the spindle rail, and roller beam to the floor
(A and B) are dimensions which influence the total length of the yarn path on
the ring frame (Fig. 9.3 (i)). Both dimensions are governed by the conditions
of the easy service of the machine.
almost to the spinning triangle and is responsible for the greater part of the
thread breaks. It is reduced to a very small degree by the division of single
large balloon into two smaller ones. Thereby considerably reduces spinning
tension and end down frequency. However spinning at low tension adversely
affects fiber orientation in yarn matrix and results in yarn with low strength.
Even yarn hairiness gets increased due to continuous yarn rubbing with ring
surface.
Normally adopted anti-balloon ring setting is half of the balloon height.
LBCR = LB/2 [Eq. 9.2]
Here ‘LBCR’ represents a distance between ring and balloon checking ring
and ‘LB’ balloon height from ring.
(spindle) speed (10−3 min−1), c = coefficient of the centrifugal force (cm−1), and
Nm = metric count of the yarn.
Hence centrifugal force required for balloon formation depends on mass
of traveller (m), ring diameter (2R) and spindle speed. Thereby for known
yarn tension Tx and spindle speed (n), traveller weight or ring diameter
values can be altered for getting desired balloon size. It will allow spinning
to continue without causing balloon to interfere with rotating bobbin
encapsulated inside. Selection of traveller count must be done in accordance
to yarn count, otherwise results in either balloon collapse or traveller fly, if
used heavier or lighter respectively. Ring diameter is changed with respect to
Spinning geometry 159
yarn count for controlling yarn tension. Smaller diameter rings are used for
finer count and larger one for the coarser one. But it may result in packages of
disproportionally small diameter, and reaching the value taken for the ration
d/D becomes impossible under mill condition.
The ratio d/D is important for defining yarn tension required to rotate
the traveller against larger radial component of winding force (FW). Smaller
the ratio higher the stress involved liable to cause frequent end breaks. In
view of the above, in practice both traveller weight and ring diameter are to
be reduced. However, within the ranges of particular yarn counts, changing
the ring are to be avoided for controlling yarn tension, i.e. package density is
controlled by changing the traveller weight only. If ring diameter is changed
it can affect the following parameters also:
(i) Yarn content of the package – Rotating bobbin is encapsulated inside
the yarn balloon formed by the traveller racing on the ring. Enough clearance
must be kept between bobbin surface and revolving traveller especially at the
biggest diameter of bobbin. Full bobbin diameter is thereby restricted by the
ring diameter. Normally adopted relationship between full bobbin diameter
(df) and ring diameter (D) is as follows:
df mm = (D – 3) mm [Eq. 9.4]
Thus amount of yarn wound on the package is limited by its full bobbin
diameter. It is higher for bigger ring diameter, results in low doffing frequency
and thereby reduced downtime of the machine.
(ii) Spindle gauge – Spindle gauge represents the axial distance between
the neighbouring spindles. In order to prevent contacts between the balloons,
a distance of at least 24 cm is provided between the spindles. The possible
maximum balloon diameter is almost 2.5 times as large as the diameter of the
ring.
Accordingly, for a ring diameter of 48 mm, in case there is no contact
between the balloons, a spindle gauge of 120 mm is to be applied. From the
point of view of exploiting spindle capacity, this value still appears to be
too high. Generalizing rings with bigger diameter makes spindle mounting
accordingly wider spaced and increases spindle gauge. Bigger spindle
gauge allows less number of spindles (production unit) per machine to be
accommodated and reduces production per machine.
A further decrease in spindle gauge may be obtained by the use of
separators. They reduce balloon diameter without considerably increasing
yarn tension.
(iii) Production rate – Limiting speed of the traveller (π DRNT) is
dependent on the combination of ring-traveller used on a frame. Thus for a
160 Engineering techniques of ring spinning
given limiting speed of traveller, if ring diameter (DR) is large then traveller
speed (NT) will be less. Spindle speed is thus restricted to lower value. Hence
spindle speed determines production rate of the ring frame. Thus for the lower
allowable spindle speed production rate attained by ring frame is also low.
leads to twist variations, count variations and higher end breaks occurs due to
continuous acceleration and deceleration of traveller speed.
On the other way excessive end break will occur if too large ring used
compared to the lift. This is due to abrupt rise in yarn tension due to bigger
diameter balloon formation. Separators need to be employed to control balloon
diameter in such case.
The normally adopted ratio of tube height to ring diameter HT/ DR is
0.2 to 0.225 for stable spinning situation. Use of anti-balloon ring becomes
mandatory, while working with longer lift package with preferable HT/ DR
ratio. Otherwise if Hmax is higher than node height (πP), balloon gets collapse
makes spinning impossible.
9.4 References
1. Klein W. (1987). ‘The Manual of Textile technology: Vol. I – The Technology of Short
Staple Spinning’, Manchester, The Textile Institute.
2. Lord P.R. (2003). ‘Hand Book of Yarn Production: Science, Technology and
Economics’, Taylor and Francis.
3. http://www.rieter.com/.../rikipedia/.../ring-spinning/.../spinning-geometry, [Accessed
on 12 July 2014].
4. http://www.nptel.ac.in/courses/116102038/23, ‘NPTEL Phase II: Textile Engineering
– Yarn Manufacture II, [Accessed on 1 August 2014].
10
Yarn tension theory
Abstract: Ring spinning is always carried out under tension. This tension has
a positive impact on yarn strength due to improved fiber orientation in yarn
matrix. Even though preferable yarn tension need to be controlled or else results
in higher end breaks when exceeds yarn strength. This demands identification
of various ring spinning parameters in three main tension zones contributing to
yarn tension. Variables need to be optimized for varieties of yarn spun on a given
set up of machinery.
Key words: Traveller, yarn tension, winding, balloon, centrifugal force, resistance
force, mass of traveller, Coefficient of Friction, normal force, spinning tension,
yarn strength, Coriolis forces, air drag
10.1 Introduction
Ring spinning is always carried out under tension. This tension has a positive
impact on yarn strength due to improved fiber orientation in yarn matrix.
Even though preferable yarn tension need to be controlled or else results in
higher end breaks when exceeds yarn strength. This demands identification of
various ring spinning parameters in three main tension zones contributing to
yarn tension. Variables need to be optimized for varieties of yarn spun on a
given set up of machinery.
for stable spinning to prevent balloon collapse between lappet guide and
ring traveller. On the contrary the balloon should not be too large to cause
excessive end breaks due to higher balloon tension.
Winding tension: It is the yarn tension prevailing between traveller and
bobbin. It defines the compactness of wound package and thereby doffing
frequency.
The yarn tension in this zone is mainly attributed to yarn pull which
makes the traveller, suspended on it, to rotate around the ring. Thus the
tension differs from the winding tension due to frictional contact made with
traveller on leaving the balloon and entering the winding section. It is reduced
to a very small degree by the diversion of the yarn at the thread guide. Thus,
winding tension get exceed by exponential component of the product of angle
of wrap at traveller θ and coefficient of friction between yarn and traveller (µ),
according to winding theory.
FW = FBeµθ [Eq. 10.12]
Where e is the base of natural logarithms.
Thus, FB = FW/eµθ
The value of angle of wrap changes with balloon size (Fig. 10.1 (iii)).
Thus, product eµθ not remains constant but also goes on changing. According
to Klein (1987), eµθ = 1.2 to 1.8. Taking the average eµθ = 1.5.
\ FW = 1.5FB [As, FB = FW/eµθ]
Substituting mathematical expression (Eq. 10.9) for yarn tension in
winding zone, the above expression will be:
FW µMd R ω2
FB = = [Eq. 10.13]
eµθ 2(Sin ∅ + µCos ∅).eµθ
Thus, balloon tension FB gets influenced by ring diameter, mass of
traveller, spindle speed, coefficient of friction between yarn and traveller and
winding on angle.
Yarn tension FB(max) at the point of maximum diameter in the balloon can
be derived approximately from the following formula given by Professor
Krause (1959):
FB(max) = k × ωL2 × H2 × σ [Eq. 10.14]
Where, ωL is the angular velocity of the traveler, H is the height of the
balloon, σ is the specific mass of the yarn, i.e. (yarn mass/yarn length) ≈ tex,
and k is a constant.
Thus, for a given yarn count, the yarn tension in the balloon is strongly
dependent upon the traveler speed and the height of the balloon. Thereby high
traveler speeds, and greater balloon heights, lead to very high yarn tensions in
the balloon.
The, major influencing factor for balloon zone tension (FB) is balloon
dimensions itself, viz., diameter and height. So, it can be varied by changing:
• Traveller speed/spindle speed for the given count. As it defines bulge
of the balloon and
• Lift of the package, as it defines height of the balloon.
Yarn tension theory 169
10.6 References
1. Chattopadhyay R. (2000). ‘Yarn Tension in ring spinning’, NCUTE – Pilot Programme
on Ring spinning, Doubling and Twisting, NCUTE Delhi, pp. 101–109.
170 Engineering techniques of ring spinning
2. De Barr and Catling H. (1965). ‘Manual of Cotton Spinning: The Principles and
Theory of Ring Spinning,’ Manchester, The Textile Institute.
3. Klein W. (1987). ‘The Manual of Textile technology: Vol. I – The Technology of Short
Staple Spinning’, Manchester, The Textile Institute.
4. Stalder H. (1994). ‘Increasing ring spindle speed in consideration of yarn quality and
running condition’ Melliand English, 7–8, E 140.
5. https://www.scribd.com/.../yarn-tension-and-balloon-geometry-in-ring-spinning,
[Accessed on 20 August 2014]
6. https://nptel.ac.in/courses/116102038/24, Yarn Tension in Ring Spinning – nptel
[Accessed on 20 August 2014]
11
Parameters influencing yarn tension during spinning
Abstract: Ring frame holds major share in yarn cost. Apart from the raw material
cost the major share to yarn cost is coming from the power cost. Out of the
total power consumption of spinning process, ring frame consumes maximum
power in comparison to rest of the spinning sections. Spindle drive absorbs major
share of energy allotted to ring frame. So, proper utilization of this larger energy
share for getting desired yarn quality at an economical rate becomes an utmost
important. The variables influencing yarn tension during spinning and thereby
added power consumption need to be identified and rectified accordingly.
Key words: Energy cost, spindle drive, traveller mass, Angle of wrap at traveller,
triangular balloon, Coriolis forces, air drag, balloon height, Angle of wind
11.1 Introduction
Ring frame holds major share in yarn cost. Apart from the raw material cost
the major share to yarn cost is coming from the power cost. Again ring frame
consumes maximum power in comparison to rest of the spinning sections and
in that spindle drive absorbs major share of energy. So, proper utilization of
this larger energy share for getting desired yarn quality at an economical rate
becomes an utmost important. The variables influencing yarn tension during
spinning and thereby added power consumption need to be identified and
rectified accordingly.
Air drag also comes into picture in the winding region, between traveller
and bobbin. If the yarn is assumed weightless, undergoing no air drag and
by neglecting the yarn axial velocity, the yarn would lie in a straight line in
winding zone (Fig. 11.1 (c)). But actually resumes curved line. Thereby to
overcome the effect of air drag, there must be a net tangential force on each
element in the direction of rotation. The moment of the tangential component
of tension increases from traveller to package, increases yarn tension.
Hence effect of air drag is complex and as mentioned before having less
influence on yarn tensioned detailed mathematical analysis is avoided.
Parameters influencing yarn tension during spinning 175
winding angle. This difference increases as the bobbin increases in the degree
of fullness. If the balloon height is too short, the value of the tension level rises
even at the beginning of winding (doff). Although balloon height is small, the
number of yarn breakages is about the same as at the beginning, of winding
due to triangular balloon formation and winding on the smallest diameter of
cop.
It is found that when winding angle becomes smaller than 23°, the radial
pull would be too high as to preclude the movement of the traveller. So, the
ratio of bobbin to ring diameter has to be suitably selected such that Ømin is
greater than 23°. Normally the minimum winding angle is kept at 25° to 30°,
to avoid higher end down at this point.
11.3 References
1. De Barr and Catling H. (1965). ‘Manual of Cotton Spinning: The Principles and
Theory of Ring Spinning,’ Manchester, The Textile Institute.
2. Klein W. (1987). ‘The Manual of Textile technology: Vol. I – The Technology of Short
Staple Spinning’, Manchester, The Textile Institute.
3. Stalder H. (1994). ‘Increasing ring spindle speed in consideration of yarn quality and
running condition’ Melliand English, 7–8, E 140.
12
Means of controlling spinning tension variations
Abstract: The spinning tension in the yarn is desirable up to certain limit but
going beyond that results in excessive end breakage. Rather than average
tension value, the peak value of spinning tension is more important in this
regard. Because when the peak tension exceeds the yarn strength, especially
at weak point in the spun yarn, it leads to end break. Apart from that, working
under a very high spinning tension results in deterioration of yarn quality. So,
measure and control to spinning tension at an optimum level throughout the cop
build need to be applied.
Key words: End break, yarn cost, spindle drive, movable spindles, dual drive,
dual motor drive, inverter motor drive, ring data, variable speed drive
12.1 Introduction
The spinning tension in the yarn is desirable up to certain limit but going
beyond that results in excessive end breakage. Rather than average tension
value, the peak value of spinning tension is more important in this regard.
Because when the peak tension exceeds the yarn strength, especially at weak
point in the spun yarn, it leads to end break. Apart from that working under
a very high spinning tension results the deterioration of yarn quality. So,
measure and control to spinning tension at an optimum level throughout the
cop build need to be applied.
The end breakage rate rises steeply with increasing spinning tension
and its variation. In this respect, the peak value of spinning tension is more
important than the average value and for a better performance of ring frame;
the peak value of spinning tension should be lower. Because when the peak
tension exceeds the strength of weak places in the yarn, it leads to end break. In
addition, a very high spinning tension results the deterioration of yarn quality
parameters, such as elongation-at-break, unevenness and imperfections.
Hence is becomes necessary to measure and control spinning tension at an
optimum level throughout the cop build.
i. Highest yarn tension occurs in the beginning of doff (Cop heel) due
to highest balloon height.
ii. Yarn tension goes on reducing with advancement due to reduction in
balloon height.
iii. Again higher yarn tension at the end of doff (Shoulder heel) due to
triangular balloon formation.
Similarly yarn tension is highest when wraps have to be formed on
the bare tube (small diameter), and lowest on the full cop circumferences
(large diameter). It has already been mentioned that tensile force (FT) must
be assumed tangential to the cop circumference because it arises from the
winding point. Frictional force (FR) undergoes only small variations; it can be
assumed to be the same in both cases. The components of tensile force (FT)
of the yarn tension are then also equal. However, owing to the difference in
the winding angle (Ø), the tensile forces FT = FW Sin Ø are different; less for
smaller angle (Ø) and higher for larger angle (Ø). The result is that the tensile
force exerted on the yarn is much higher during winding on the bare tube than
during winding on the full cop diameter because of the difference in the angle
of attack of the yarn on the traveller.
When the ring rail rises during layered winding, i.e. from a large to a small
winding diameter (slowly upward but faster downward pace), yarn tension
increases substantially, and ends down frequency increases accordingly.
According to a study carried out by Zinser, most thread breakages occur when
the ring rail rises in the upper (not the highest) zone. In order to maintain
thread tension and ends down at constant levels, spindle speeds should be
reduced when the ring rail is raised (control of layering speed).
However, the yarn tension at any instance of cop building is the net effect of
both the variables (balloon height and winding diameter). Thereby yarn tension
is substantially higher when the ring rail is at the upper end of its stroke, than
when the ring rail is at its lowest position, in spinning onto the tube.
Tension variations are not occurring only at the particular point of cop
winding (e.g. formation of the base); but arise at very short intervals in each
ring rail stroke. However, balloon tension is decisive between two. Thereby,
highest tension is recorded in the beginning of doff. This drops progressively
with the build-up of the bobbin diameter and reduction in balloon height.
Although at the end of doff, winding is carried out with smallest balloon, its
triangular shape increases yarn tension again. Additionally highest winding
tension is prevailing at the minimum diameter (tip) of the bobbin. Net effect
of both shows rise in yarn tension at the end of doffs but still less by 1.35 times
to the beginning of doff. This is mainly attributed to domination of balloon
tension over winding tension.
182 Engineering techniques of ring spinning
in synchronization with ring rail concept on all ring frames. In this concept
during layering traverse and switching traverse, lappet guide and balloon
control ring also moves in synchronization with ring rail, as explained in
earlier section of builder mechanism. However, their magnitude of movement
is restricted by spinning geometry. Hence the system maintains balloon height
almost constant, yarn tension variations gets minimized (Fig. 12.2 (b)). Apart
from these lighter parts participates in the movement, so power consumption
is less. No complications arise in drive as ring rail do not bear any positively
driven element like spindle. So, system assures quality at an economical rate
as compared to earlier concept.
start-up step (to prevent start-up thread breakages), a base step (for forming
the cop base) and a normal step (for winding the cop as a whole). Since tension
rises at the top most position (Fig. 12.3 (i)), there is often also a spin-out step
for winding the topmost part of the cop, which can be identical to the base
step.
Different options available on conventional to latest modern ring frame
to serve the purpose. Definitely they are differing in terms of working pattern,
accuracy and economy. They are as follows:
i. Dual speed drive
ii. Dual motor drive
iii. Variable speed drive
iv. Inverter motor drive or frequency-controlled drives
Figure 12.3 (i- iii) Methods used for controlling yarn tension during the doff
Figure 12.3 (iv- v) Methods used for controlling yarn tension during the doff
is kept higher for low end breakage rate and low for higher rate. Going one step
ahead, this microprocessor software for inverter control drive is alliance with
Programmable Logical Control [PLC] Unit in addition to Ring Data. Group
of ring frames equipped with software and ring data system can be controlled
through a PLC unit from a remote place also. Thus system promises unlimited
scope to alter the machine speed as per requirement. There is no mechanical
linkages used, makes system sturdy and robust. There are no mechanical
losses.
The major shortcomings are:
• It demands higher initial investment as well as sophisticated
maintenance.
• Higher power consumption because of AC to DC and DC to AC
conversions.
• Higher temperature rise at the inverter demands installment of
efficient cooling system.
• Sudden impact caused with increase or decrease in traveller speed
along with spindle speed liable to reduce traveller life.
• Apart from these drawbacks this system is unbeaten till date.
12.6 References
1. Booth, J.E. (1975). Textile Mathematics (Vol. II), The Textile Institute, Manchester,
p.333.
2. De Barr and Catling H. (1965). ‘Manual of Cotton Spinning: The Principles and
Theory of Ring Spinning,’ Manchester, The Textile Institute.
3. Klein W. (1987). ‘The Manual of Textile technology: Vol. I – The Technology of Short
Staple Spinning’, Manchester, The Textile Institute.
4. Mahajan S.D. (March 2000). ‘Drives on modern ring frames’, NCUTE-PILOT
Programme on Ring Spinning, Doubling and Twisting, pp. 23–25.
5. Stalder H. (1994). ‘Increasing ring spindle speed in consideration of yarn quality and
running condition’ Melliand English, 7–8, E 140.
6. https://nptel.ac.in/courses/116102038/24, Yarn Tension in Ring Spinning - nptel
[Accessed on 20 August 2014]
7. https://www.schlafhorst.oerlikontextile.com/.../Ring/2014_06_Zinser_Roving_
Frame, [Accessed on 20 August 2014]
13
Optimization of ring spinning parameters
Abstract: Spinning parameters like ring diameter, lift of the package, traveller
mass and spindle speed have a greater influence on the quality and cost of ring
frame and thereby the entire ring spinning. It becomes necessary to optimize
these ring-spinning process parameters in order to curtail cost and increase the
production rate without affecting the yarn quality.
Key words: Productivity, ring diameter, spindle gauge, capital cost, labour
cost, doffing, limiting speed of front roller, traveller limiting speed, surface
characteristics, piecing efficiency, traveller mass, balloon size, production rate,
package power, yarn content
13.1 Introduction
Spinning parameters affecting productivity of the ring frame and thereby
the entire ring spinning. It becomes necessary to optimize the ring-spinning
process parameters in order to curtail cost and increase the production rate
without affecting the yarn quality.
weight and package weight. Hence spindle weight is constant for the given set
up; the magnitude of efforts goes on changing with respect to package weight.
Power required to rotate the package is referred as package power (P). Bigger
and heavier package gets build up with bigger diameter ring, according to the
relationship,
Full package diameter = Ring diameter – 3 mm [Eq. 13.2]
The package power (P) also changes relatively. The experimentally
derived relationship between them is as follows:
P ∞ D2.75 [Eq. 13.3]
Thus power consumed increase 2.75 to the power of ring diameter. This
hike the yarn cost considerably.
(ii) Effect on labour cost: Full bobbin diameter is restricted by the ring
diameter (D). It is always kept 3 mm lesser than ring diameter for ease of
traveller rotation as mentioned above. Smaller the ring diameter, then
smaller the allowable full bobbin diameter and there by its yarn content.
Approximately,
Package Capacity ∞ Ring Diameter2 [Eq. 13.4]
Modern ring frames operates with smaller diameter ring. So, allowable
yarn content of the package is less. Higher delivery speed of the machine, the
package builds up fast and increases doffing frequency. Manual doffing is the
time consuming exercise, increased down time of machine for higher doffing
cycles adversely affects machine efficiency. Thus modern ring frame are
equipped with auto doffing, to shorten doffing time considerably few seconds
instead of 30–40 minutes. But it demands additional initial investment and
maintenance cost. However, increased machine efficiency with its higher
production rate can pay back it in a short time. Similarly, use of larger diameter
ring on conventional ring frame without auto doffing can be well justified.
(iii) Effect on capital cost: Spindle gauge, ‘center to center distance of
two consecutive spindles on ring frame’ is dependent on the measure of ring
diameter. As explained in spinning geometry, permissible balloon diameter
is based on ring diameter apart from other factors. So, minimum viable
allowance needs to be kept between two neighbouring spindles. Thus bigger
the ring diameter higher is the spindle gauge value. This permit less number
of spindles to be get accommodated on the given length of machine. Reduced
number of working heads per machine demands more number of machines
to be installed to meet the desired production rate. The initial investment for
procuring higher number of machines, space occupied, labour employed,
power consumed, maintenance, etc. associated with production course are
accordingly higher.
Optimization of ring spinning parameters 193
Summarizing the entire discussion the yarn cost involved is higher while
spinning with large diameter ring than smaller one. However, use of auto
doffing system is mandatory for ring frames with smaller diameter rings.
spindle rpm, and traveller speed limitations. Although a large diameter ring
increases yarn tension as well as cost, it is thought desirable, for spinning
heavier thicker counts. The yarn is strong enough to withstand the increased
tension and a larger package can be build up without facing excessive end
breaks. Higher yarn content of cop reduces doffing frequency and thereby
unproductive downtime of ring frame. These frames with less number of
spindles are normally provided with manual doffing option for imparting
economy.
On the contrary, smaller rings are employed while spinning finer counts
along with auto doffing system. This helps in attaining desired centripetal
forces with the traveller mass, chosen according to the linear density of the
yarn being spun. Thus ensures spinning of good quality and economy of
costlier yarn. Higher investment for auto doffing is offset by reduced labour
cost and number of machines.
In practice selection of ring diameter depends on
• Quality of raw material and yarn
• Yarn count
• Production rate / spindle speed
• Availability of labour, their cost and type
Looking at the other side of the coin, practically attainable spindle speed
is always lower than the one claimed by the manufacturer. Limiting speed of
the traveller (TL), surface speed of front roller and end breakage rate are the
major controller in this regards.
Influence of limiting speed of the traveller (TL): Thermal damage cause
to traveller at higher friction between ring-traveller is referred as traveller
blueing or burning. The friction between ring-traveller increases with spindle
speed. So, it becomes necessary to run spindle (thereby traveller) below the
speed causing traveller burning. This speed is known as limiting speed of
traveller. Thus spindle speed gets restricted by traveller limiting speed. Its
value differs as per type of ring-traveller, their surface characteristics (type of
material) and amount of twist. That’s why ORBIT ring-traveller can permit
high spindle speeds in comparison to T-ring and C-shape traveller combination
(Table 13.1).
m/min attained in the latter case. The value for inclined drafting system can
be enhanced further by imparting proper training and giving incentives to the
workers up to 25 m/min.
Effect of limiting front roller speed on the allowable spindle speed can be
explained by example.
Example: Let’s assume two yarns, one is coarser (9 Ne) and another
finer (64 Ne) spun with identical twist (T.M. = 4) on the modern ring frame
provided with orbit ring–traveller system and inclined drafting. The limiting
speed of front roller for the given machine set up is 25 m/ min.
Spindle speed (rpm)
TPM = [Eq. 13.10]
S.S. of front roller (m/min)
Where,
94.6 T
\ nmax < [Eq. 13.13]
π N
Accordingly maximum attainable spindle speed is less for finer yarn (low
value of N) and more for coarser yarn with the virtue of an end break.
13.3 References
1. Azarschab, M. and Renner, G. (1995). ‘Influence of high speed
spinning on the properties and downstream processing of yarns’,
Melliand Textileberichte, p. 964.
2. Carl A. Lawrence (2003). ‘Fundamentals of Spun Yarn Technology’,
CRC Publications.
3. Datta, B., Kanjilal, S.K., Bagga Anil, and Mehta, N.C. (1983).
‘Optimum package size in ring spinning frame-I’, The Indian Textile
Journal, p.73.
4. De Barr and Catling H. (1965). ‘Manual of Cotton Spinning: The
Principles and Theory of Ring Spinning,’ Manchester, The Textile
Institute.
5. Eric Oxtoby (1987). ‘Spun Yarn Technology’, Butterworths & Co.
Ltd., London.
6. Hasanuzzamana, Pranab K. Dana and Sanghita Basu (2014).
‘Optimization of ring-spinning process parameters using response
surface methodology’, Journal of Textile Institute, Taylor & Francis
Online, Accessed on 25 August 2014]
7. Klein W. (1987). ‘The Manual of Textile Technology: Vol. I – The
Technology of Short Staple Spinning’, Manchester, The Textile
Institute.
8. Lord P.R. (2003). ‘Hand Book of Yarn Production: Science,
Technology and Economics’, Taylor and Francis.
14
Material handling
14.1 Introduction
Labour Employment Ratio (LER) is one of the major indices in defining and
controlling productivity of spinning units. As labour is another major contributor
to yarn cost apart from raw material and power cost. Raw material cost can be
optimized by using scientific methods of mix formulation techniques, which
are beyond the scope of this book. Various measures are taken for optimizing
power consumption of ring frame. Spindle drive is the major power absorber
of the entire ring spinning system. The measures taken for optimizing power
consumption at this end have already been discussed in Chapter 12. Thus left
behind variable is the labour compliment. Almost 50–60 percent of total skilled
and unskilled labours are employed in ring frame section only for classical
mode. They involved in various activities like, machine operation, maintenance,
cleaning and material handling. Out of total unskilled labours almost 50–60
percent is involved in the material handling activities. Manual material handling
is an obvious candidate for the faulty production, production delay and higher
storage, also adds to labour cost. It becomes obvious that material handling can
be made automatic on longer length high production ring frames. However, it is
done with higher initial investments.
of creeling, doffing, transporting full cops from ring frame to winder and
roving bobbins from speed frames to ring frames, handling Bonda waste.
Whereas skilled labours like tenters, jobbers, etc., were dealing with process
control and machine maintenance exercises like, count change over, settings,
conducting rounds for idle spindles, snap study, piecing, initiating doffing
and restarting with new doff, etc. Industries were normally seeking for the
trained personnel for these jobs by paying higher wages. But the unskilled
labours involved in material handling mainly, were not able to earn higher
wages. However, keys for the quality of end product were lying in the hands
of such labours only, even though having a less share in ring frame labour
cost.
Faulty manual material handling practices were liable to create havoc.
As an example cross mixing of material (roving) of parallel counts running
in mill, leads to higher un-assorted product waste and badly impacting yarn
realization of the mill. This is mainly attributed to human fatigue comes out
of monotonous or ergonomically unsuitable working environment.
to the cops, at the production speed of the winder units, in a direct line to
the downstream winder after doffing. Emptied tubes return to the doffer‘s
loading station on the ring spinning machine. The number of winder units
has to be chosen to ensure that the winding of doff is completed exactly when
the next approaches. The exact coordination between the two machines is
necessary otherwise it can be a great drawback of the system. If there are
frequent yarn count changes, then reserve winding capacity often remains
unused needs to be installed to provide for every eventuality. This results in
higher capital service costs. These systems are therefore ideal when operating
as far as possible with only one yarn count.
14.5 References
1. http://www.rieter.com [Accessed on 24 October 2014]
2. http://www. rikipedia.com [Accessed on 24 October 2014]
15
Measures of process control
15.1 Introduction
Process control in terms of machine parts condition, precise setting of process
variables and meeting specifications of product quality parameters is the
inherent feature for the success of any production house. Conventional ring
spinning system depends on the human expertise for the purpose being, thereby
lagging in terms of quality and quantity of production gained. However,
sensor-based online monitoring and control system of modern high-speed ring
frames have made this labour intensive exercise simple and precise.
consuming snap study for controlling end breaks and section wise and spindle
wise rounds for identifying causes for non- productive spindleage were taken
by skilled operators. These visual inspection was followed by brain storming
long statistical evaluation of data, before initiating corrective measures for
improving machine efficiency and thereby productivity. Even manual piecing
was done at the event of en down. Thereby not only piecing efficiency gained
was low but also human bias variations in the quality of piecing. Product
verification was off line and passing through time consuming, tedious non
automatic testing procedures. Even these practices demand lot of material
handling between production house and quality control center. Non-automatic
mode of testing was adding to skilled labour factor involved in ring frame
section. Slow testing speed followed by manually done statistical evaluation
before deriving conclusion were delaying the corrective measures taken for
preventing faulty production.
The conventional system thereby suffering from following major draw
backs:
(i) Higher LER at ring frame section due to human-based measures and
control
(ii) Human bias and delays in corrective measures
(iii) Absence of system for identifying cause of problem demands time
consuming and human bias exercises like snap study and spindle
rounds
(iv) Low machine efficiency and production rate due to higher percent
end breaks and percent idle spindle in the house
(v) Higher waste levels due to low piecing efficiency
‘Spider Web’ and ‘POLYLINK’ by Zellweger, etc. Few examples are mentioned
below to highlight working mode of such systems and the precision and ease of
control imparted by them in comparison with classical tedious exercises.
Ring data system consists of a traveling sensor, known as traveler, runs
continuously back and forth at the height of the ring rail on each side of the
machine on a single machine (pilot unit) or on all machines in the mill. This
generates a magnetic field that is affected by the rapidly rotating traveler. If
a yarn break occurs, the traveler ceases to rotate and the sensor displays the
resulting impulse as an end down, also recording the number of the spindle. As
a result of its rapid motion back and forth it registers the spindle several times
until the end down is repaired. Thus precise recording of spindle downtime
becomes possible. Another sensor fitted on the front roller records the delivery
speed and machine stoppages, thus gives exact record of production rate and
loss of fibers in Bonda waste as per the count running on ring frame. One
more sensor keeps the track for the number of doffs and their duration. All the
information collected is ultimately transmitted to a computer with monitor and
printer, which performs the necessary analysis and stores the data for preset
periods. The following data are available via reports on individual machines,
individual blends or the installation as a whole that are printed out or can be
called up on the monitor any time:
• Machine number
• Date
• Time
• Period monitored
• Production period
• Spindle speeds
• Yarn twist
• Output in kg
• Output in g/spindle /hr.
• Efficiency
• Downtimes
• Doffing times
• Number of cops doffed
• Number of ends down
• Ends down per 1000 spindle hours
• Mean duration of ends down
• Preset maximum number of ends down
• Number of spindles with ends down exceeding this limit
Measures of process control 209
(ii) Soft keys provide direct access to the data displays important for
operation.
(iii) Microprocessor based analysis of data provides quick response to
address the problems.
(iv) The time until the next doffing process is indicated directly on the
basic display.
Thus optimization of process control system improves efficiency and the
allocation of personnel. Minimize human share and associated errors from the
production course.
15.4 References
1. http://www.rieter.com [Accessed on 24 October 2014]
2. http://www.rikipedia.com [Accessed on 24 October 2014]
3. http://www.lakshmimach.com [Accessed on 24 October 2014]
4. http://www.toyota-industries.com [Accessed on 24 October 2014]
5. Klein W. (1987). ‘The Manual of Textile technology: Vol. I – The Technology of Short
Staple Spinning’, Manchester, The Textile Institute.
6. Stalder H. (1994). ‘Increasing ring spindle speed in consideration of yarn quality and
running condition’ Melliand English, 7–8, E 140.
Index
M S
Manual doffing 144 Saddle 33
Movable spindle rail 182 Scavenger Roller 38
Sensor monitoring drive 209
Separator 54, 55
O
Servo grip 141
Open creel 10, 13 Short apron 24
Orbit ring–traveller 66, 71, 86, 88 Shoulder heel 120, 184
Skewer 11
P Spacer 26
Package power 192, 195 Spindle 7, 104, 157
Piecing Efficiency 197 Spindle design 105
Pneumafil 38– 39 Spindle gauge 8, 159, 192
Production rate 159 Spindle speed 101, 108, 167, 196
Spinning 1, 2, 5, 164
Spinning angle 151
R Spinning Geometry 150
Regular creel 10 Spinning stability 101, 150, 159
Ring 5, 56 Spinning triangle 44, 152, 154
Index 213
Switching traverse 118, 124 V
Su-ring 66, 83 Variable speed drive 185
Vibrating string theory 97
T
Tangential belt drive 112 W
Tape drive 109
Wave length 98
Top arm 5, 31, 32
Top rollers 18 Wharve 106
Traveller 5, 66 Winding 5, 104, 114
Traveller canting 66 Winding diameter 180
Traveller mass 72.168, 172, 199 Winding force 166
Traveller speed 76, 83, 115 Winding on angle 76, 159, 175
Twist 49, 88
Twisting Mechanism 49
Y
U Yarn content 159
Yarn tension 163, 166, 180, 198
Under winding 131