3.

Fabric Manufacture-I (NTT-302)

Unit (3): Ways of yarn traversing, Machine traverse ratio, angle of wind,
conicity of cone, packages, ribbon formation and method of its
elimination, package density, winding parameters, package defects
during winding and their remedies.
WAYS of YARN TRAVERSING:

Yarn traversing methods are as follows:

 Reciprocating traverse mechanism

 Rotating traverse mechanism

With reciprocating traverse successive coils of yarn are laid close

and parallel to each other on the package, it is possible to
produce very dense package in which a maximum amount of yarn
is stored.

With rotating traverse cross wound package are prepared in

which the pitch between the successive coils is large and
considerable number of voids are created, therefore package is
less dense.
Reciprocating traverse mechanism
Rotating traverse mechanism
WIND AND TRAVERSE RATIO:

‘Wind’ is the number of revolutions made by the package

during the time taken for the yarn guide to make a traverse in
one direction across the package.

The wind indicates, the number of coils of yarn laid on the

package surface per single traverse.

The ‘traverse ratio’ is the number of coils laid per double

traverse of yarn guide, therefore traverse ratio is twice the
wind.
ANGLE OF WIND: It is angle at which yarn is wound on the
cone. It is an angle made by the yarn with the perpendicular to
the cone axis.
CONICITY OF CONE: The cones used for high speed warping or
processes that demand a high take-off speed are normally taper
from base to nose with a small taper angle of 6° and as the cone
builds up, the original taper angle is maintained by the cone.
PACKAGE DENSITY:

Package density depends on the yarn traverse mechanism,

winding tension and cradle pressure.

It is possible to produce very dense package with reciprocating

traverse as successive coils of yarns are laid parallel to each
other, whereas with rotating traverse cross wound package are
prepared and package is less dense.

Package density is also influenced by winding tension & cradle

pressure and with the increase/decrease of either of two
package density could be increased or decreased.
PACKAGE DEFECTS:
 
Stitch/Jali: Yarn falling on either side of cone, a jail is
formed on the sides of the cone.
 
 

 
 
   

 Effect:
More breaks will occur in subsequent machinery
More hard waste will be produced. 
Reasons:
 Setting of cone holder with drum is not correct or vibrations
in the cone holder.
 Yarn would on the sides of cone holder.
 Alignment of tension brackets with drum is not correct.

Remedy:
 Check frequently cone holder setting and alignment of
tension bracket with drum.
Ribbon: Ribbon pattern is formed over the cone surface.
 
 
 
 
 
 
 
 

Effect:
Yarn bunches comes out during unwinding which increases
hard waste.
Reasons:
 Rotation of winding drum is not proper.
 Setting of cone holder with drum is not correct.
 Anti patterning device not working efficiently.
 Alignment of tension brackets with drum is not correct.

Remedy:
 Ensure proper movement of cone holder by lubricating
the cone regularly.
 Keep care of maintenance of machine
 Check anti patterning device time to time.
Soft Build Cones: When loose yarn is wound on cones,
soft build cones are produced.
 
 
 
 
 
 
  
 
 

Effect:
Sloughing off of layers of yarn is possible during unwinding
process. This will increase hard waste and more yarn
breaks.
Reasons:
 Low pressure on cradle.
 Low winding tension.

Remedy:
 Check pressure of cradle and set it right.
 Check tension device and clean it time to time so that
proper tension is maintained.
Bell Shape Cone: In this type of cones yarn is wound at
more tension at the center portion of cone.
This produces bell shape cone.
 
 
 
 
 
  
 
 

Effect:
Such cones cause more ends break at Subsequent process.
Reasons:
 Winding of yarn on cone at high tension.
 Setting of cone holder with drum is not correct.
 Middle portion of proper cone is damaged.

Remedy:
 Check empty cones before put to use.
 Unwinding yarn tension from bobbin should be checked.
 Check cone holder setting.
Nose Bulging: When yarn in the form of bunches
accumulates near the cone tip, then the defect is called
nose bulging.
 
 
 
 
 
 
 
 

Effect:
Yarn comes out in bunches when such cone is rewound.
Reasons:
 Setting of cone holder with winding drum is not correct.
 Cone tip is broken or damaged.

Remedy:
 Check different settings in the machine at regular intervals.
 Workers should be motivated for adopting only correct
method of working.
 Never use broken or damaged cones.
Collapsed Cones: If the cone is pressed or damaged after the
yarn is wound on the cone, the defect is called collapsed cone.

 
 
 
 
 
 
  

Effect:
Excessive breaks and more hard waste in subsequent
process.
Reasons:
 Use of broken or very old cones.
 Material handling methods improper.
 Winders do not follow proper system of working.

Remedy:

 Motivate workers for systematic work culture.

 Use trolley for carrying cones from one place to another.
Ring Shaped Cones: In this type of cones, one ring type projection
of yarn is formed on the outer surface.
 
 
 
 
 
  
 

Effect:
Increase in hard waste in subsequent process.
Reasons:
 Due to scratches in the drum groove, the yarn is arrested
at some point, which causes yarn winding at one point.
 Setting of cone holder is not correct.
 Tension assembly not working properly. 
Remedy:
 Check drum for cut or scratches, repair is possible or
change.
 Check cone holder setting and tension assembly at regular
intervals.
RIBBION FORMATION AND METHOD OF ELEMINATION:

Patterning take place when the succeeding coils of yarn are

placed exactly on the preceding ones. It happens when the ratio
of the rotational speed of the package and that of the traversing
unit is a whole number.
Packages with ribbon formation show increased tendency for
sloughing-off during unwinding and uneven dye pick-up in the
case of dyed packages.

Proper selection of the ratio on winding machine eliminates the

possibility of ribbon formation. On drum driven winding
machines, the ratio changes continuously during the build up of
the package and there are certain phases when the ratio tends
to be a whole number. There is a ribbon formation for short
intervals.

Therefore, most of the drum driven winding machines are

equipped with anti patterning device to prevent the ratio to be a
whole number. The proper functioning of this device should be
ensured.
QUALITY & NORMS IN CONE WINDING
 
Quality Norms
 
Cone weight variation + 50 gms per package
 
Breakage per lac meters Winding Rewinding
 
Below 20s 14 – 16 6–8
21s – 40s 8 – 10 3–5
40s and above 6–8 2–4
 
TENSION WEIGHT:
 
Tension weight in grams = 0.259 x Lea strength in lbs x 1.8
TENSION IN THE YARN:
 
Type of winding m/c Speed Level of tension
Medium speed winding m/c Up-to 650 meters 1/10 single yarn
per minute strength
 
High speed winding m/c above 650 meters per 1/8 x Single yarn
minute and above strength
 
SLUB CATCHER SETTING:
 
Carded count = 2.0 x Diameter of yarn
Combed count = 1.5 x Diameter of yarn

0.95
Diameter of yarn = ----------
in mm. Count
NORMAL CLEARING EFFICIENCY AND KNOT FACTOR:
 
Type of slub catcher Clearing Efficiency Knot factor

Mechanical slub catcher

 Fixed Blade 2 – 10 3.5

 Serrated Blade 5 – 15 2.5 – 4.0

Electronic Slub Catcher 70 – 80 Up-to 1.7 or less

PRODUCTION OF CONE WINDING:
 
Winding speed x 60 x 8 x 1.0936
(in meters/min)
Prod. Per shift per = -------------------------------------------------------
Drum in kg. 840 x Count x 2.2