Winding

Limitations of Spinning Technology

 Progress in spinning – automation and productivity
 Despite of progress, it is still not possible to produce a
fault-free yarn
 Depending on the raw material and state of the
machinery park, there are about 20 to 100 events over a
length of 1000 km yarn
 Yarn exhibits a yarn faults every 1 to 5 km.
 Yarn faults – too thin, too thick, foreign fibre and dirty
places
 Spinning process leads to formation of disturbing faults
 Reasons for Disturbing Yarn Faults
1. Machine parts - worn out or out of tolerance
2. Contamination – trash, dust, seed coat fragments
3. Foreign material
 These yarn faults cause disruptions in subsequent processes –
productivity and quality
 Hence spinner has to fulfill the demand of fault free yarn by two
measures
1. Prevent origin of yarn faults by adequate measure
- Choice of raw material, m/c maintenance and cleanliness in
mill
2. Remove yarn faults by the aid of yarn clearers
- Winding process
 Winding Machine
Objects of Winding:
1. Extraction of disturbing yarn faults
2. Conversion of smaller package to bigger package
3. Waxing of the yarn during winding process
4. Clearing foreign fibres
5. Clearing of Polypropylene
6. Detection of off-standard bobbins
7. Monitoring frequent yarn faults
8. Monitoring & documentation of quality data
Passage of Yarn through Winding Machine
 Yarn Faults
 Textile industry is dividing the yarn faults in
1. Frequently occurring faults
- Tested on Evenness Tester
- Expressed per 1000 m of yarn
2. Seldom occurring defects
- detected & eliminated during winding
- expressed per 1,00,000 m of yarn
 Difference between Frequent faults & Seldom occurring

defects is mainly larger mass or diameter deviation and size

 Classification of Yarn Faults
1. Neps
• Faults that are less than 1cm and having a mass
increase of more than 100% are called Neps
Neps
• They are basically produced due to immature
fibres / seed coat fragments in the raw material,
very short entanglements of fibres and yarns.
2. Short Thick Places
• Faults with a length of 1 cm to 8 cm and having Short Thick

a mass increase of more than 100%

• These faults are basically produced due to short
fibres, improper draft control, bad piecing, flies
in spinning
3. Long Thick Places
• Faults with a length of more than 8 cm and
Long Thick
having a mass increase of more than 45% are
called Long Thick places.
• These faults are basically produced due to
thick places in sliver, roving etc.
4. Thin Places
• Faults with a length of more than 8 cm and
having a mass decrease of more than 30% are Long Thin
called Thin places
• These faults are basically produced due to
missing sliver in drawing, stretches in sliver
and roving etc.
5. Count variations
• Faults with a length of several meters and
having a mass increase / decrease of more than Count

5% are called count variations

6. Foreign matters
• Faults with a length of more than 1 mm and
visibility level of more than 5% are called
Foreign Fibres
foreign matters
• They are primarily produced due to mix up of
colour fibres, jute, hair, seed particles etc.
Fault size (%)
Yarn Fault Classification Matrix

Fault length in (cm)

 Spectrum of Yarn Faults

+ 6 0 0%
+ 5 0 0%
+ 4 0 0% S h o rt
T h ic k L o n gT h ic k P la c e s
+ 3 0 0%
P la c e s
+ 2 0 0%

+1 0 0 %
Im p e r fe c tio n s

0 U ne ve nn e ss

L o n gT h in P la c e s
-1 0 0 %
0 .1 1 2 4 8 16 32 64 . . . . . . . . F a u lt L e n g th (c m )
 Basic setting of N S L T
 For an easy setting of clearing limits Thick places are divided in to NSL
classes and
 Thin place expressed as T
 N – channel - Less than 1 cm (to clear nep faults)
 S – channel – 1.0 to 8.0 cm (to clear short thick place faults)
 L - channel – up to 200 cm (to clear long thick place faults)
 T - channel – up to 200 cm (to clear thin place faults)
Class Clearing Curve
 Electronic Yarn Clearing
Yarn Faults Removing Principle

1. Yarn faults monitored by an

electronic device
2. As soon as yarn clearer detects a
yarn fault, the yarn will be
separated by the cutter
interrupting winding
3. Yarn fault removed by the suction
of the winding machine
4. Yarn splicing or knotting
5. Winding process continues up to
next fault
 Yarn Fault Measuring Principle
• Thickness of the yarn monitored and converted into a proportional
electrical voltage signal
• Sensor monitors a yarn running up to 120 km/hr and , the yarn is
measured every 2 mm
• Signal conversion is carried by –
 Capacitive measuring principle or
 Optical measuring principle
 Capacitive Measuring Principle
1. Electrical measuring
condenser
2. Two electrodes
3. Electrical alternating
voltage
4. Yarn
5. Electrical signal

 Electrical signal corresponds to the yarn cross-section yarn mass

 Changes of the yarn mass cause a proportional change of signal
 Optical Measuring Principle

1. Infrared light source

2. Diffuser
3. Photocell
4. Yarn
5. Electrical signal

 Electrical signal corresponds to the diameter of the usually round

yarn
 Changes in yarn diameter cause a proportional change of signal
 Foreign Fiber Clearing
• Cotton can be contaminated the cotton field to the spinning mill
• Human and animal hair, feathers, strings, packing material, stems, leaves and oil stains
• Foreign fibers –cause fabric defect, lower the efficiency of the following processes
Detection of Foreign and Polypropylene Fibers
• Optical measuring system
• Comparison between the reflection of the foreign fiber and the normal yarn color
Classification Matrix - Uster
Classification Matrix - Loepfe