Limitations of ring spinning

Insert Twist by Rotating Yarn?

Technological
Yarn tension (traveller drag, balloon)
Traveller speed
Heat
Draft system
Static Yarn

Economic
Large package size required (fewer
knots, fewer replacements) but larger
package requires more power to drive
and faster traveller speed
Cause of Problem:
Twist Insertion Requires Package Rotation

Open-End (Break) Spinning Principle

Twisting

Moving Yarn
False
Twist

No Twist

Twisting

Advantage of Open End Spinning

Smaller mass involved in twist insertion higher speed

Break in Fibre Flow
No spinning balloon lower yarn tension
Twisting

Fibre
Transfer

Winding

Fibre Supply

Package formation independent from twisting larger

size, choice of form, reduced winding

Spinning direct from sliver no roving

Brief History of Open-end Spinning Development

1876 J Hibry

USP173290 J Hibry 8 Feb. 1876

Brief History of Open-end Spinning Development

1876, J Hibry
1937, Svend Ejnar Berthelsen

Svend Ejnar Berthelsen GB477259 24 Dec. 1937

Brief History of Open-end Spinning Development

1876, J Hibry
1937, Svend Ejnar Berthelsen
1955, ITMA Brussels, Spinnbaus Meimberg eMKa-Spinner

Svend Ejnar Berthelsen GB477259 24 Dec. 1937

USP3119223 Julius Meimberg 2 July 1956

USP3119223 Julius Meimberg 2 July 1956

Brief History of Open-end Spinning Development

1876, J Hibry
1937, Svend Ejnar Berthelsen
1955, ITMA Brussels, Spinnbaus Meimberg eMKa-Spinner
1960s, Intensive R/D in many countries

Brief History of Open-end Spinning Development

1876, J Hibry
1937, Svend Ejnar Berthelsen
1955, ITMA Brussels, Spinnbaus Meimberg eMKa-Spinner
1960s, Intensive R/D in many countries
1965, KS 200, the first machine with drafting rollers
exhibited in Czechoslovakia
1966, BD200 installed in factory
1967, ITMA Basel, Switzerland, Elitexs BD200, 30,000 rpm

BD200b

Brief History of Open-end Spinning Development

Common requirements of open-end spinning

1876, J Hibry
1937, Svend Ejnar Berthelsen
1955, ITMA Brussels, Spinnbaus Meimberg eMKa-Spinner

Fibre separation device

Means of fibre transportation

1960s, Intensive R/D in many countries

Device for collecting separated fibres
1965, KS 200, the first machine with drafting rollers
exhibited in Czechoslovakia

Device for rotating open-end of yarn (twisting device)

1966, BD200 installed in factory

1967, ITMA Basel, Switzerland, Elitexs BD200, 30,000 rpm
1971, ITMA Paris, wide spread commercial introduction
2003 8m rotors 174.5 m ring

Yarn take-off and package build mechanism

Key feature of open-end spinning:
Separation of twisting from winding, but
continuous operation

Critical point: yarn property

Most successful system: rotor

Rotor Spinning Principle

Rotation of Yarn Arm

Inserts Twist in Yarn

Air Exit

Yarn Delivery

Rotor

Nozzle
Fibre
Transport
Channel

Feed Roller
Opening
Roller
Feed
Shoe

Sliver

Trash

Opening Roller

Rotor

Nozzle

Example of Fibre Mass Attenuation

Feed
Roller

Fibre
Speed
(m/s)

Draft

No. of Fibres
In
Cross Section

Opening
Roller

0.015

Rotor
Groove

Yarn Withdraw
Point

100

200

2.5

30

2000

20,000

Exit of Fibre
Transport Tube

10

1/80

1.5

120

Yarn Arm

Fibre Transport Channel

Yarn Twist

Twist in Yarn:
t=

Ny
Vd

Yarn Arm
Rotation
Ny (rpm)

Vd = (Ny-Nr) D

Nr
Vd

t=

Nr
Vd

Vd

Rotor Diameter = D (m)

Nr
Ny-Nr

Back Doubling:

Production rate (kg/h):

Vd

D
Ignored

Nr
Vd
D

Nr
D
Vd

t = Nr
Vd

Back Doubling: t D

Yarn Peel-off Point

Moving Relative to
Rotor =
Yarn Delivery Speed
Vd (m/min)

Nozzle

Vd
Ny = Nr +
D
t=

Rotor
Rotation
Nr (rpm)

tex
1

60 E N
1000 1000

tD

Important Rotor Parameters

180
160

120
100
80

Rotor Diameter
D

60
40
20
0
1967 1972 1977 1982 1987 1992 1997 2002 2007

Rotor Speed and Diameter

Rotor Diameter D

160000
Smaller rotor

Higher speed

120000
Max. RPM

Thousand RPM

140

Must have sufficient size so that longest

fibre does not form a complete loop

80000

Minimum D > Staple Length

40000
Current minimum: 28 mm

0
28

32

36

40

44

48

52

56

Rotor D (mm)

Important Rotor Parameters

: 30-60o

Opening Roller Speed

Thicker yarn:
Larger D &

Groove Angle

Higher speed gives better fibre opening

: 12-50o
Smaller for
Higher Rotor
Speed

Rotor Diameter
D

Rotor Groove

If opening roller speed is too high, fibre

striping by air may not be complete, leading
to more yarn faults

Optimum depends on fibre, yarn and rotor speed

Rotor Wall Angle

Opening Roller Type

Working angle

Type of wire (pin or saw-tooth)

Point density
Working angle

Pin Type

Saw-tooth Type

Rieter Opening Roller Wire

Draw-off Nozzle
Steel draw-off nozzle:
For man-made fibres and blends

Effects of
Draw-off Nozzle surface

No static charging
Lower surface nozzle temperature

Grooved nozzle increases false twist, helps to

spin yarns with lower machine twist (e.g. knitting
yarns)

Ceramic draw-off nozzle:

More hard wearing, longer life

Yarn rolling against

stationary nozzle surface
Stationary
Draw-off Nozzle

Effects of
Draw-off Nozzle surface

Grooved nozzle increases false twist, helps to

spin yarns with lower machine twist (e.g. knitting
yarns)

False Twist in Yarn

inside Rotor

Grooves disrupt fibres in yarn, increasing

hairiness and yarn faults

Rotating Yarn Arm

Effects of
Draw-off Nozzle surface

Grooved nozzle increases false twist, helps to

spin yarns with lower machine twist (e.g. knitting
yarns)
Grooves disrupt fibres in yarn, increasing
hairiness and yarn faults
Higher false twist increase wrapper fibres
during untwisting by nozzle

Ring Spinning and Rotor Spinning Comparison

Loose fibre disorientate

& crimp in airflow

Fibre straightening and

parallelization by drafting
Fibre under tension
through the process

Yarn Formation
Fibre Disposition
Fibre straightness/alignment
Wrapper fibres
Fibre hooks
develop on
Opening roller

Ring Spinning and Rotor Spinning Comparison

Yarn Formation
Fibre Disposition
Fibre straightness/alignment
Wrapper fibres

Wrapping of fibre forms

when incoming fibre attached
twisting yarn arm

Fibre migration

Spinning Triangle

Front
Drafting
Rollers
Core Fibres Migrate
outwards

Surface Fibres
Under Higher
Tension
Migrate inwards

To spindle

Ring Spinning and Rotor Spinning Comparison

Yarn Formation
Fibre Disposition
Fibre straightness/alignment
Wrapper fibres
Fibre migration

False twist depends

on nozzle friction

Twist structure

Ring Yarn Twist

Rotor Yarn Twist

All fibres twisted

at same time
with same t
Yarn formed gradually from core outwards

Highest tension

Fibres near core

has lower twist angle
& under lower tension

Fibres deposited first (towards the core) has higher twist

Fibres are twisted under low tension: low fibre straightness
Twist differential & wrapping fibres make twisting testing difficult

Ring Spinning and Rotor Spinning Comparison

Yarn Formation
Fibre Disposition

Ring Spinning and Rotor Spinning Comparison

Yarn Properties
Tensile properties
Evenness

Fibre straightness/alignment
Wrapper fibres
Fibre migration

Aesthetic properties
Hairiness
Abrasion resistance

Twist structure

Others

Yarn properties

10

Ring Spinning and Rotor Spinning Comparison

Ring Spinning and Rotor Spinning Comparison
Raw material requirements

Techno-economics
Investment
Fixed costs

Fibre length

Operating costs
Raw materials/waste

Fibre fineness
Maintenance

Fibre strength

Labour

Effects of drawing

Energy

Impurity content

Product value
Application
Fibre type
Yarn type and end-use

Machine Example

Ring Spinning and Rotor Spinning Comparison

Ring Spinning

Rieter R 40
Material cotton, man-made fibres and blends up to 60 mm

Wider yarn count range

Feed weight 7.00 to 2.5 ktex

Suitable for most fibre types

Draft 40 to 400

Good yarn tensile, hand and aesthetic properties

Yarn count 200 to 10 tex

More preparatory processes

Low speed

Twist 196 to 1500 T/m

Package weight max. 6 kg (max. 350 mm )

High power requirement

Rotor 28, 30, 31, 33, 36, 37, 40, 41 46, 47, 48, 56, 57 mm
Small bobbin
Opening rollers 64 mm
High doffing frequency (lower efficiency/higher labour cost
Draw-off nozzles ceramic in various designs

Rotor Spun Fancy Yarns

Limited to fibre effects (mainly slubs)
Variable motor driven sliver feed
Difficult to produce abrupt changes
Minimum length D due to back-doubling

Rotor Spun Fancy Yarns

Other developments
Special opening roller (using negative
working angle for cotton so that fibres
accumulate on roller and produce random
bundles in yarn) (0.5-4 inch length slubs)

Multi-twist effects (altering yarn twist randomly)

Cover yarns

11

Cover
Yarn

Core Yarn

Staple Yarn

12