Beruflich Dokumente
Kultur Dokumente
Presentation
on
AUTOCONER 21C
Madan Regar
M.Tech
(Textile Engineering and Management)
Department of Textile Technology
WINDING
Ring spinning produces yarn in a package form called cops. Since cops from
ringframes are not suitable for further processing, the winding process serves to
achieve additional objectives made necessary by the requirements of the
subsequent processing stages.
Following are the tasks of winding process
Extraction of all disturbing yarn faults such as the short, long thick , long
thin, spinners doubles, etc.
Manufacture of cones having good drawing - off properties and with as long
a length of yarn as possible
paraffin waxing of the yarn during the winding process
introduction into the yarn of a minimum number of knots
achievement of a high machine efficiency i.e. high production level
Main Specifications
Maximum winding speed 2,000 m/min
Balloon control : Bal-Con (brush type kink preventers integrated type)
Tension control : Tension manager
Drum drive : DBL motor (direct drive)
Drum : * Pac21 (100 parallel drum), It is designed to support P
winding, parallel winding, Q winding, and soft winding. 2.0 W
and 2.5 W possible (6-inch traverse), High-speed unwinding
to avoid ribbon winding (pattern winding)
Winding angle : 3 30, 4 20, 5 57, 0
Traverse length : 108 mm (4 inches), 152 mm (6 inches)
Splicer : Cassette type, VOS communication type
Cradle : It is designed to support P winding, Q winding, and
parallel winding (bearing center: optionally available).
Contact pressure : Contact pressure control device by compressed air
(group-by group)It is designed to support soft winding.
Residual yarn feeler : Photoelectric feeler compatible with colored yarn
Tension release : Electrical tension release
Blower system Equipped with power-saving inverter
Winding unit Each winding unit has error/problem indicating function provided
Other optionally available functions:-
Mach Splicer
Splicing Operation
Yarn take-in Push the upper and lower yarn into
the splicer using the yarn guide levers, and then
clamp them there.
Cutting of the yarn ends the upper and lower yarn
cutters cut the ends of the upper and lower yarn.
Untwisting
The cut yarn ends are sucked into the untwisting pipe
and untwisted.
Splicing
The yarn guide lever is pushed in until it comes in contact
with the splice length control lever (Ln), pulling the yarn
end out of the untwisting pipe by the appropriate length.
While the yarn ends are out they are held by the yarn holding
lever, and a jet of compressed air from the splicing nozzle
tangles and twists the yarn ends together to complete the
splicing.
Hot Splicer
Hot Splicer is a device that uses hot compressed air for splicing.
Wool fabrics become soft when heated, making it easier to splice. By heating
up the twisting air, Hot Splicer is able to set optimum conditions for splicing.
While splicing worsted yarn with an Air Splicer, one needs to change settings,
parts and to perform complicated adjustments, depending on the type of yarn.
Hot Splicer requires no such adjustments, thus dramatically reducing the
maintenance time.
Mechanism of Hot Temperature Air Supply
Similar to the conventional Air Splicer, Hot Splicer also has untwisting
(black) and a splicing (red) air lines for compressed air. They are connected
to twisting pipe and splicing nozzle respectively.
The air heater, which is inserted into the 2nd valve, instantly heats up the
splicing air. The hot splicing air is supplied to the splicing nozzle, which
also has a built-in heater that maintains the temperature of nozzle as well as
the splicing air.
Water Splicer
The water splicer is a device that uses water to splice two yarn ends. By
mixing water particles with the twisting air, it is possible to splice yarn that
could not be spliced by an air splicer.
The splices that are created using the water splicer I have the following
characteristics.
It is possible to knot yarn types unsupported by the air splicer (two-ply
cotton yarn, and wet-spun linen, etc.)
The use of water provides a stronger and more stable splice part.
The use of water suppresses the hairiness of the splices.
Water Supply Mechanism
Like the conventional air splicer, the water splicer is equipped with an
untwisting air line and twisting air line. These are connected to the
untwisting nozzle and twisting device respectively.
The water supply line (blue line) is connected to the downstream side of the
twisting air line valve. Through the supply of a fixed quantity of water to
the twisting air line, the water that is on the line before the release action of
the twisting air valve will be ejected together with the compressed air when
the valve is released.
The water particles ejected during the splicing action are prevented from
dispersing into the surrounding area by a cover that covers the splice part.
The water that collects inside the cover is drained out of the machine via a
separately installed suction line.
Splicing Action
(1) Release of water valve:- The cam connected to
the yarn guide lever pushes the water valve and this
supplies water to the twisting air line.
N - NEPS
S- SHORT FAULTS
L-LONG FAULTS
CCP - COARSE COUNTS
CCM-FINE COUNTS
There are very high demands for both measuring principles regarding the
resolution and precision of the results. The sensor must be able to monitor a
yarn which runs with up to 120 km/h through the sensor and to detect even
very short faults. In order to achieve this, the yarn is measured every 2 mm.
The capacitive measuring principle
The electrical measuring condenser (1) forms the sensor for the capacitive
monitoring of the yarn mass. This is done by two parallel metal plates, the
electrodes. In the space in between (2), the two electrodes build an electrical
field when putting on an electrical alternating voltage (3). If a yarn (4) is
brought into this field, the capacity of the measuring condenser is changed.
From this change, an electrical signal, the yarn signal (5) is derived. The
change in the capacitance depends, besides of the mass of the yarn and of
the dielectric constant of the fiber material used, on the moisture content of
the yarn.
With the capacitive measuring principle, the yarn signal corresponds to the
yarn cross-section yarn mass, respectively, which is located in the measuring
field. Changes of the yarn mass cause a proportional change of the yarn
signal.
The optical measuring principle
The infrared light source (1) and the photocell (3) represent the sensor for
the optical monitoring of the yarn thickness. The infrared light is scattered
by a diffuser (2) in the light field and reaches the photocell (3). The
photocell emits a tension, which is proportional to the amount of light. If a
yarn (4) is brought in the light field, parts of the light will be absorbed by
the yarn. The amount of light, which hits the photocell, is smaller. From
this change, an electrical signal, the yarn signal (5) is derived.
Influences on yarn measurement and yarn clearing
Influence Capacitive measuring Optical measuring
principle principle
Fiber material Most fiber materials can be Fiber material n be measured with both measuring
principles.
Yarns, which contain electrical
conductive fibers, cannot be processed.
Colored yarns No or only little influence Color differences within the bobbins
can lead to malfunctions
Fiber blends No or only little influence
Wax If the wax device is located below the yarn clearer, there is the tendency of a dirty
measuring field. The selection of a suitable wax can keep the contamination within
acceptable limits.
Contamination Usually, the measuring field cleans itself to a great extent by the yarn hairiness. In
certain limits, the yarn signal change, which is caused by the contamination, is
compensated electronically. When the limits of the compensation are reached, a
technical alarm for the respective iMK is triggered.
Atmospheric Normal variations in the humidity have no influence.
humidity
Yarn humidity Normal variation have no influence as long as the yarn structure is not changed.
WAXING PROCESS
Waxing is the process which is almost exclusively used in all automatic and
manual winding machines for yarns which are meant for knitting. This
helps to reduce the coefficient of friction of yarns created during knitting
process.
Extensive tests have shown that the coefficient of friction of waxed yarn is
not constant, but depends on the amount of wax on the yarn. It is proved
that both too little and too much wax cause increase in coefficient of
friction and thus detrioration in running efficiency on the knitting machine.
The recommended wax pick up for different material are given below:
cotton and its blends - wax take-up of 1.0 to 2.0 grams per kg of yarn
synthetics - wax take-up of 0.5 to 1.5 gram per kg of yarn
wool and its blends - wax take-up of 2.0 to 3.0 grams per kg
A further problem can arise during steaming, or any other treatment involving
the application of heat to a waxed package.
Low yarn tension will affect the wax pickup
Dimensions and form of wax rollers will affect the wax uniformity
As it is clear and is important that, if the waxed particles are to carry out
their function, they must remain on the surface of the yarn. When the yarn
is subjected to heat however, the wax melts and penetrates to the inside of
the yarn body: it can then no longer work effectively.
When choosing the wax, it is essential to consider the type of yarn and
fibre, the temperature in the production area, etc., and the characteristics
indicated by the wax manufacturer
Winding process
The best winding speed is the speed which allows the highest level of
production possible for a given type of yarn and type of package, and with no
damage whatsoever to the yarn.(abrasion and breaks due to excessive tension)
Selection of Winding Speed
(1) Without Bal-Con
(2) With bal-con
The graph above shows winding speed examples for different types of yarns
with spinning bobbins designed especially for high-speed winding. This is not
always the same, according to the type of spinning bobbin or winding
conditions.
Winding speed depends upon the following factors:-
Sloughing
Type and characteristics of bobbin
Take-up tube
Count
Type of yarn, (type of fiber, average strength and minimum strength)
Package taper
Final use of package
For high-speed winding, it is essential to minimize sloughing. It is difficult
to remove sloughing completely with a yarn clearer and this can adversely
affect the quality of shipped packages.
Causes of Sloughing
The causes are listed below in order of frequency.
1) Number of coils (chase length) ............42%
2) Winding speed .................................................................................17%
3) Height of balloon breaker ...............................................................13%
4) Hardness of spinning bobbin ..........................................................12%
5) Relation between balloon breaker height and number of coils ......4.5%
6) Relation between winding speed and number of coils ...................4%
7) Others ............................................................................................7.5%
Type and characteristics of bobbin
The accuracy and strength of the take-up tube is important for a high-speed
winding of 1,200 m/min or more. Insufficient accuracy and strength of the
take-up tube may cause drop-out of the package from the holder during
winding. An increase in the winding speed also increases the risk.
.................................................................................3 15 to 5 57
L .................................................................................170 to 178 (1) mm
t ..................................................................................2 mm or more
Fluctuation at smaller diameter side at part A ............0.2 mm or less
Resistance to the force from F ...................................20 kg or more
D and d eccentricity .............................................None
d and D diameter variation ................................... 0.2 mm or less
Take-up tubes with a V or U-shaped cutout, as shown in the photos below,
can easily be deformed when the package brake is activated, possibly
causing the package to step wind or come off, and therefore their use is not
recommended.
V-shaped U-shaped
Ribbon Winding
Ribbon Winding:-A ribbon winding is a rope-like pattern in which the
wound yarn is superimposed in approximately the same position.
This cannot be avoided if a conventional drum is used.
As shown by a in figure, the yarn is wound with a displacement. This
displacement is almost zero for an approximately 200mm diameter package
with a 2W drum, and for an approximately 250mm diameter package with a
2.5W drum, and a single-wind large ribbon winding is produced when the
drum diameter is 100 mm.
For the following reasons, this single-wind ribbon winding presents the
most difficult problem with high-speed unwinding.
(1) As the diameter of the package is considerable, the unwinding yarn
balloon does not readily expand.
(2) The cross-point between yarns is limited to one point on the ribbon
winding, and the force holding the yarn in the package surface layer is
minimal.
Drum Wind Control (jumping system)
Control Mechanism:- 2-winds, 1.5-winds, and single-wind winding on the
package surface is liable to result in a ribbon winding with both 2W or
2.5W winding.
The drum wind controller is therefore used to form a package suitable for
high-speed unwinding by switching the number of winds at before and after
this particular package diameter.
when the drum wind controller is not operating the yarn is introduced into
the outer groove (i.e. the groove with the 3W winding angle (lead angle)).
When the drum wind controller operates the yarn is introduced into the
inner groove (i.e. the groove with the 2W winding angle (lead angle)).
Drum wind
controller
Controlling the Number of Winds The drum wind controller controls the
number of drums in order to prevent the number of winds on the package
surface from reaching 2 winds, 1.5 winds, or single wind. The VOS screen
automatically sets the timing of activating the control of the drum wind
controller.
The wound package is shown in the figure.
Poor Winding Shape
Cause Action
[1] Bulge The internal compression is increased as (1) Lower the number
winding the winding diameter is increased due to of drum
the increase in the contact pressure of wind (from 2W to
the package on the drum or to the 1.5W)
increased density of the yarn. Thus, the (2) Tension release is
internal yarn layers buckle. This occurs necessary for coarse
with coarse yarn and two-ply yarn. yarn or bulky yarn.
(1) Winding angle is too large. (3) To reduce contact
(2) Winding tension is excessive. pressure, a pressure
(3) Contact pressure is too high. reducer is necessary.
[2] Wrinkles This is caused by short traverse at the (1) Improve the
start of winding, reduced tension by tension and contact
slipping, and also by the bulge winding. pressure.
(1) Inadequate tension and contact (2) Remove defective
pressure. take-up tubes.
(2) Deflection of take-up tube center. (3) Correct the small
(3) Poor adjustment of contact surfaces diameter driving of
of take-up tube and drum. take-up tubes for
(4) Excessive application of increase. paired drums.
Cause Action
[3] Scramble (1) Drum does not stop at yarn (1) Replace the yarn
breakage. clearer. Check MS2.
(2) Joining motions repeats several (2) Check the joining
times. motion and yarn path.
(3) Suction mouth comes in contact Also check the splicer.
with package. (3) Adjust the suction
(4) Contact pressure is too low. mouth stopper.
(5) Ribbon comes off.
[4] Stitch The yarn is dropped off the edge of 1) Set the tension
package. properly.
(1) Inadequate tension or variation of (8 to 12% of single
tension. yarn strength)
(2) Flaw near the drum nose. (2) Correct the flaw on
(3) Improper rotation of cradle the drum.
bearing center. (3) Replace the cradle
(4) Loose cradle. bearing.
(5) Improper position of drum to (4) Correct the loose
cone holder. cradle.
(6) By ribbon winding. (5) Adjust the cradle.
(7) By sloughing. (7) Increase the
(8) By low humidity (hemp, acrylic) humidity to 60%
or more.
Cause Action
[5] End missing At the winding end of spinning 1. Increase the humidity
bobbin or at yarn breakage, yarn end (60% or more).
is wound on the either end of the take- 2. Remove the cause for
up tube or wound into the package sloughing.
layer. 3. Improve the spinning
(1) Improper gap between the drum process.
cover and the package. 4. Improve the spinning
(2) Excessive sloughing. bobbin building
(3) Excessive surface cut of spinning (spinning process) or
bobbin. lower the winding speed.
(4) Winding speed not suited to
spinning bobbin building.
[6] Ribbon This is most likely to occur when the (1) Change the
winding ratio of the drum diameter and disturbance setting.
package diameter is an integer. (2) Lower the contact
With rotary traverse type of winder, it pressure.
is not possible to completely prevent (3) Replace the bearing
ribbon winding, but dispersing is of cradle if the rotation is
possible. heavy.
(1) Improper setting of disturbance.
(2) Excessive contact pressure.
(3) Improper rotation of cradle.
Cause Action
[7]Stepped (1) Flaw on drum. (1) (2)Check the flaw
winding (2) Flaw on drum cover. and repair by sanding.
(3) Low tension. (3) Increase the tension.
(4) Disengaged yarn from the (4) Be careful not to
yarn path after machine cleaning. blow the yarn when
cleaning with air.
[8] (1) Improper guiding of yarn to 1) Check and correct
Pattern winding the tensor. any flaw on yarn guide.
(2) Foreign substance on tensor. (2) Clean the tensor.
(3) Excessive variation in (3) Check and improve
unwinding tension due to the spinning bobbin
improper forming of spinning building.
bobbin.
(4) Low increase. 4) Improve the increase.
(5) Bal-Con adjustment problem. (5) Adjust the Bal-Con.
(6) Low tension. (6) Increase the tension.
Cause Action
[9] Saddle back (1) Over tension. (1) Lower the tension.
package (2) Low contact pressure. (2) Increase the contact
(3) Low increase. pressure.
(3) Improve the increase.