M09 Spinning - State of The Art

M09 Spinning - State of the Art
Prof. Dr. Alexander Bsgen

Spinning
Productivity of Spinning
System Age at 2012
(Years)
Productivity
[m/min]
Ring Spinning
Rotor Spinning
Air Jet Spinning
Source: McCreight et. al., Shart Staple Yarn Manufacturing, Carolina Academic Press, Durham (NC) 1997
192
42
31
18
150
350
Ring Spinning 2009:
185 Million spindles worldwide produce 70% of all staple fibre yarns
?
Exercise:
Market Position of Ring Spinning
Group Work:
Discuss the Reasons
for the continued market success
of Ring Spinning!
Reasons for Market Succes
of Ring Spinning
Reasons for continued ring spinning success:
- Superior yarn properties
- surpassing versatility (fibre materials, yarn counts)
- easy to handle machine technology
- well established process know-how
Principle of
Ring Spinning
Roving
Drafting system
Spinning
triangle
Spinning
axis
Pigtail guide
Bobbin
Ring Traveller
Ring rail
Spindle tape
V
1
V
2
Machine settings:
- Positionings and spacings of the
drafting system
- twist and twist multiple (TM)
- ring-traveller system
- spindle rotation speed
Shape of Spinning Triangle -
Yarn Quality Impact
Short triangle:
+ Less yarn breaks
- More hairiness
Long triangle:
- More yarn breaks
+ Less hairiness
Compact Spinning
DREF Spinntester (ATME 1989)
Pneumatic
compacting of
slivers to
eliminate
roving frames
for ring spinning
pneumatic split of
fibres into two
compacting by
air pressure
introduced by
Dr. Ernst Fehrer
at ATME 1989
Principle of Compact Spinning
twisting causes fiber concentration on one side
fibers of this high concentrated side are twisted nearly 100%
fibers of the opposite side are barely twisted:
hairiness fibers
compact spinning:
compaction of fibers before twisting,
closing the triangle opening,
causing all fibers into twisting
Compact Yarn:
Spinning Triangle and Yarn Structure
Ring Spinnig Compact Spinnig
Principle of
Compact Spinning
Morgner, J., Analyse und Optimierung des Verdichtungsspinnensim Hinblick auf Wirtschaftlichkeit und Garnqualitt,
phd thesis, Stuttgart University 2003
1 drafting unit
1a compacting device
1b perforated apron
2 balloon having a new
yarn structure
3 traveller
4 ring
5 spindle drive
6 ring bank
7 cops
8 balloon limitation
9 thread guide
10 spinning triangle
11 roving
E point of compaction
CompACT System of Zinser
Perforated Metal Drum (Comfortspin by Rieter)
Core Elements of Comfortspin (Rieter)
compacting and parallelizing after main draft, high efficiently air guiding unit
Air guide elements enhance the condensing zone
Additional nip roller prevents the twist from being propagated into the condensing zone
Comparison of Ring- and Compact Yarn
Morgner, J., Analyse und Optimierung des Verdichtungsspinnensim Hinblick auf Wirtschaftlichkeit und Garnqualitt,
phd thesis, Stuttgart University 2003
Raw material costs = 50 - 60% of yarn costs!
Can compact spinning manufacture ring yarn quality using less quality yarns?
(e.g. cheaper yarns having more short fibre content)
Processing of Compacted Yarn
twisting: less turns / m required
sizing : reduction of 20% - 50%
warping: 29% reduction of yarn breakage
weaving: 50% reduction of yarn breakage
Rotor Spinning
Open End Rotor Spinning
Picture: Rieter
Spin box
Separation of
fibres
straightened
conveyance
through
air velocity
channel
Rotor
Opening
roller
Fibre
channel
Yarn Formation
Picture: Schlafhorst
Rotating, brush-like
open yarn end
catches
1. core fibres, then
2. peripheral fibres
(gradually)
Binding zone
Naval
Properties of Rotor Yarn
Core-Twist Characteristic:
harder handling,
lower strength,
good abrasion restistancy
- Core: twisted, more compacted, harder
- Sheath: less twisted, some avoid twisting-in
a) wrap fibres
(fly directly onto fully created yarn, when rotor passes feed passage)
b) low or reverse twist fibres
(false twist between naval and binding-in zone,
latecoming fibres get only a fraction of twist level,
reversed by cancellation of false twist of the main strand)
Rotor Yarn Count
Rotor yarn
quality at
higher spinning
speed
Average values
of spinning
mills
(Source:
Suessen)
Airjet Spinning
Characteristic of Air Jet Spinning
processing of staple fibres
yarn formation by swirled air
elemination of high speed rotating machine parts
(e.g. ring spindle, centrifuge of rotor spinning)
different systems in use simultaneously
false twist principle mostly favoured
new and unique yarn structure
(wrapping fibres and untwisted core)
Fascaited yarn structure
wrap fibers
untwisted
core fibers
twisted yarn
yarn after
untwisting
Air Jet false twist principle
1. 2.
source: Oxenham, W., Fasciated yarns - a revolutionary development ?,
Journal of Textile and Apparel, Technology and Management, Vol. 1, Issue 2, 2001
Early Air-jet system by DuPont
drafting rollers
false twist unit to winding unit
yarn core ist twisted,
then untwisted
edge fibres are not twisted into yarn core
but produce wrapper fibres
as they pass through false-twist unit
Principle of Air-Jet Spinning
Air-Jet Spinning
Murata Jet Spinning (MJS) in the 1980s
miniaturisation of the
spinning chamber
(only 3 - 3,5 mm diameter)
false twist process
use of compressed air
generates two air jets
(primary: swirl chamber
secondary: inlet channel)
improved yarn quality
used for polyester or
cotton/polyester blends
100% cotton can not be
processed
source: Witczak, D. et al, Air Flow in the Air-jet False-twist Spinning Chamber,
FIBRES&TEXTILES in Easter Europe Jul/Sep 2007, Vol 15, No. 3, pp. 45-48
MJS Yarn structure
source: Witczak, D. et al, Air Flow in the Air-jet False-twist Spinning Chamber,
FIBRES&TEXTILES in Easter Europe Jul/Sep 2007, Vol 15, No. 3, pp. 45-48
Tenacity vs. air-jet pressure
source: Miao, M. et al
The insertion of twist
into yarns by means of
air jets. Part 1: An
experimental study of
air-jet spinning.
Journal of the Textile
Institute, Vol 78 (1987)
No. 3, pp. 189-204
two contra-
rotating jets
two jets twisting
in the same
direction
one jet
Effect of yarn count
source: Oxenham, W., Fasciated yarns - a revolutionary development ?,
Journal of Textile and Apparel, Technology and Management, Vol. 1, Issue 2, 2001
Effect of yarn count on tenacity
source: Puttachaiyong, S. et al Properties of jet-spun poly-cotton yarns
Textile Asia, Vol. XXIII (1992), No. 10, pp. 52-55
note: increase of count increases no. of fibres in yarn cross section !
Source: Rikipedie - alternative spinning systems (www.rieter.com)
Comparison of Air-Jet Yarn Strength
Limitation of Air Jet Spinning
maximum of 5% fibers for wrapping
too short fibers cannot be processed
low strength of coarse yarns
only man-made fibers or man-made fiber rich blends with
cotton
relatively harsh hand of fabrics
Vortex Spinning Principle
non rotating
yarn core
air vortex
waste
twist-stop prevents
twist to propagate
until nip point of
draft system
Yarn Formation in Vortex Spinning
Vortex
Spinning
Process
of Murata
Air Jet
Spinning
principle by
Rieter
Fiber transport from front rollers
(Murata MVS)
fibers are
conveyed
absolutely
parallel to each
other
15% to 30% of
fiber ends are
separated from
the main flow
Speed of Air and Fibers in the Nozzle
air vortex rotation: 2 Mio - 3 Mio revolutions/min.
fibre bundle rotation: 200.000 - 300.000 revolutions/min.
Consequences:
1. until today, we cannot see the yarn formation
2. yarn formation mechanism is thus deduced from
structure analysis
Core Spun MVS Yarn
Source: Muratec, Japan
Yarn structure of Jet and of Vortex Yarns
Jet Yarn Vortex Yarn
Source: Oxenham, W. et al; Fibre motion and yarnd forming in high speed air flows
in National Textile Center Annual Report: November 1999
Core-sheath structure of Vortes yarn
Core sheath structure of untwisted Vortex yarn
source: Oxenham, W. et al; Fibre motion and yarnd forming in high speed air flows
in National Textile Center Annual Report: November 1999
Fibre selection for MVS yarns
medium to long fibers in the laydown.
more similar to a ring-spun laydown than an open-end (OE) laydown
higher SFC% (Short Fibre Content) negatively affects yarn quality
Vortex yarn characteristics
Disadvantages:
not suitable for yarn counts coarser than Ne 12/1
lower tenacity than ring yarns
Advantages:
remove of short fibers -> less yarn imperfections
varying levels of hairiness with new Murata components
excellent resistance to pilling and abrasion
capable of spinning 100% cotton
high speed production up to 450 m/min
Comparison of MVS with MJS
Energy of Vortex vs Ring Spinning
Comparison of Yarns
Rotor Air Ring Compact
Yarn Type Comparison
Pictures: Rieter
Comparison of Yarn Structure
(Ring, OE Rotor, Vortex)
Vortex yarn with sythetic fibers:
-large zero twist area
-stronger twisting at outer side
Comparison of water absorption
(Ring, Vortex)
Comparison of Pilling
Comparison of speed and yarn count
(MVS, OE Rotor, Ring)
Source: Cotton Incorporated, Technical Bulletin TRI 1001, 2004

M09 Spinning - State of The Art

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M09 Spinning - State of the Art

Prof. Dr. Alexander Bsgen

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