Dr. B R Ambedkar National Institute of Technology

Jalandhar 

Presentation on

AUTOCONER 21C   

Madan Regar

M.Tech

(Textile Engineering and Management)

Department of Textile Technology

WINDINGWINDING

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 SpecificationsMain 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 (ø100 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:-Other optionally available functions:-

* Auto Doffer (AD) (with automatic threading function) * Package conveyor (Maximum load: 180 kg) * Blow cleaner * Hairiness-reducing device * Waxing device (reverse/forward rotation) * 3-tier nozzle splicer * Water splicer * Splicer for high-twisted yarn * Bobbin stripper * Dust collector * Bracket for lighting equipment * Centralized suction blower * Fisherman knitters (quick change type)

AUTOCONER 21C AUTOCONER 21C Magazine TypeMagazine Type[1] Bobbin length is 280 mm or less[1] Bobbin length is 280 mm or less

AUTOCONER 21C Magazine TypeMagazine Type[2] Bobbin length is 281 mm or more[2] Bobbin length is 281 mm or more

AUTOCONER 21C [3] Bobbin Tray Type and Link Coner Type[3] Bobbin Tray Type and Link Coner Type

Bal-Con (Bobbin Tray Type)Bal-Con (Bobbin Tray Type)

Mechanism :- Bal-Con is intended to keep the winding tension at a constant level throughout the operation of winding yarn from the spinning bobbin to a full package. Bobbin tray type Bal-Con is integrated with a kink preventer. It includes a fixed Bal-Con part, movable Bal-Con part, sensor, air cylinder, and brush.

Operation of the Kink Preventer and Bal-Con (1) The brush on the kink preventer holds the top of the bobbin during splicing, preventing kinks

from occurring (see the upper figure on the right). (2) When the yarn starts running after it has been spliced, the kink preventer opens and Bal-Con

lowers. (3) When the sensor detects the bobbin chase*1, Bal-Con stops lowering. *1 See the

lower figure on the right. The top of the bobbin is tapered to facilitate unwinding the yarn. (4) As the yarn from the bobbin is wound onto the package, the bobbin chase

lowers. (5) When the sensor detects the lowering bobbin chase, Bal-Con also

lowers again. (6) If the yarn breaks during winding, or when the winding has been completed,

Bal-Con returns to its upper end position (home position).

Tensioner & Pre-clearerTensioner & Pre-clearerIt is possible to perform winding with a constant winding tension all the time by controlling the tensor solenoid voltage for gate tensor pressure application at the start of the drum after yarn splicing or at the end of spinning bobbin winding.The winding tension generally used is 8% to 12% of the single-yarn strength.Pre-clearerIt is possible to adjust the pre-clearer clearance by changing the adjusting lever position according to the scale on the tensor box.◊ The adjustment range is 0.4 to 1.8 mm; eight different levels available, i.e., it can be adjusted in units of 0.2 mm.◊ Set it in accordance with the yarn count setting.

Bottom view of the pre-clearer

SPLICINGSPLICING A high degree of yarn quality is impossible through knot, as the knot itself is

objectionable due to its physical dimension, appearance and problems during downstream processes. The knots are responsible for 30 to 60% of stoppages in weaving.

Splicing is the ultimate method to eliminate yarn faults and problems of knots and piecing. It is universally acceptable and functionally reliable. This is in spite of the fact that the tensile strength of the yarn with knot is superior to that of yarn with splice. Splicing is a technique of joining two yarn ends by intermingling the constituent fibres so that the joint is not significantly different in appearance and mechanical properties with respect to the parent yarn. The effectiveness of splicing is primarily dependent on the tensile strength and physical appearance.

In these machine the splicing system are:- Mach splicer Hot Splicer Water Splicer

Mach SplicerMach Splicer The Mach Splicer overlaps the yarn ends from the package and

bobbin sides, twists them together using compressed air, and splices them together without a knot. The Mach Splicer can join a broad range of natural and synthetic fibers of fine to coarse count in the same time that it takes a mechanical knotter.

Mach Splicer

Splicing OperationSplicing 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 SplicerHot SplicerHot 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 SupplyMechanism 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 SplicerWater 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 MechanismWater 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 ActionSplicing 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.

(2) Setting the yarn in position .The yarn guide lever pushes the top yarn and bottom yarn in the splicer and then the yarn is clamped (by the clamp plate).

(3) Yarn end cut/Untwisting :-The top yarn and bottom yarn ends are cut by the upper and lower cutter. The cut yarn is sucked into the untwisting nozzle and untwisted by an beater.

(4) Splice:- The yarn guide lever is pushed in so that it reaches the position of the Splice length control lever (Ln), and the yarn ends inside the untwisting nozzle are pulled out to the appropriate length. After this, a lid blocks the nozzle slit and at the same time the compressed air of the twisting nozzle is ejected. This causes the yarn ends to intertwine with each other and a twist is applied to complete the splice.

Effect of Variables on the Properties of the Spliced yarnEffect of Variables on the Properties of the Spliced yarn

The effect of various variables on the properties of the spliced yarn.Effect of Fibre Properties and BlendEffect of Yarn FinenessEffect of Yarn TwistEffect of Different Spinning MethodsEffect of Opening PressureEffect of Splicing DurationEffect of Splicing LengthEffect of Splicing ChamberComparison of Dry and Wet SplicingThe comparative studies on dry and wet splicing with water showed that the breaking load retention for wet spliced yarns are significantly greater than dry spliced yarns. In fact, wet splicing is more effective for yarn made from long staple fibres and for coarse yarn. This may be due to higher packing coefficient resulting from wet splicing.

YARN FAULTS AND CLEARING:YARN FAULTS AND CLEARING: It is still not possible to produce a yarn without faults for various reasons.

Stickiness of cotton can contribute to the formation of thick and thin places. Fly liberation in Ringframe department is one of the major reasons for short faults in the yarn because of the fly gets spun into the yarn. Hence it is not possible to have fault free yarn from ring spinning, it is necessary to have yarn monitoring system in the last production process of the spinning mill. As physical principle for electronic yarn clearing the capacitive and the optical principle have established. Both principles have their advantages in specific applications.

The quite extensive application of electronic yarn clearing has set new quality standards with respect to the number of faults in spun yarns.

It is therefore necessary to evolve a method of yarn fault classification  before clearing the faults in winding. The most important aspect is  certainly the determination of  the fault dimensions of cross-sectional size and length. With such a cross-section and length classification and by means of the correct choice of the class limits, the characteristic dimensions of the various fault types can be taken into consideration, then a classification system will result which is suitable primarily for satisfying the requirements of yarn clearing and yet allows, to quite a large extent, for a selection of the various types of faults.

N - NEPSS- SHORT FAULTSL-LONG FAULTSCCP - COARSE COUNTSCCM-FINE COUNTS

FIG: YARN CLEARING CONCEPT OF USTER QUANTUM CLEARER

Yarn clearing Yarn clearing

MAIN FUNCTIONS OF THE USTER® QUANTUM CLEARERThe main functions are:The elimination of disturbing thick and thin placesForeign fibersShort and long yarn count deviationsDetection of ring-spinning moiréDetection of deviations of the yarn irregularity (CV)Detection of hairiness deviationsMonitoring of winder functionsDetermination of quality characteristicsTriggering of alarms when preset alarm limits are exceededGenerating reports

Principle of yarn clearingPrinciple of yarn clearing 1. During the winding process from bobbin to cone, the yarn is completely

monitored for yarn faults with an electronic device, the yarn clearer. 2. As soon as the yarn clearer detects a yarn fault, the yarn will be

separated by the cutter. The winding process is interrupted. 3. The yarn fault will be removed by the suction of the winding machine.

4. Both ends, the upper yarn from the cone as well as the lower yarn from the bobbin, are going to be combined again. The yarn joint is done by splicing with a splicing device or knotting with a knotting device. The latter is only used very rarely for special yarns. A good splice should not be realized by the human eye. Present yarn clearer also monitor the quality of the yarn joint.

5. The winding process continues up to the next fault or until there is no yarn on the bobbin anymore.

Structure of the USTER® QUANTUM CLEARER Structure of the USTER® QUANTUM CLEARER The basic version of the USTER® QUANTUM CLEARER can be

expanded by several features and options. Fig. shows the different possibilities. The figure shows the dependencies from each other. Of course, it is possible to combine other features of the USTER® QUANTUM CLEARER with each other depending on the quality requirements.

In the USTER® QUANTUM CLEARER, the conversion is carried out either with the sensor of the capacitive measuring principle or with the sensor of the optical measuring principle. The sensor is part of the intelligent measuring head iMK which also consists of the electronic system to convert mass or diameter variations into an electric signal.

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 principleThe 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 principleThe 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 clearingInfluences on yarn measurement and yarn clearing

Influence Capacitive measuringprinciple

Optical measuring 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.

Atmospherichumidity

Normal variations in the humidity have no influence.

Yarn humidity Normal variation have no influence as long as the yarn structure is not changed.

WAXING PROCESSWAXING 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 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 SloughingThe 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 bobbinType and characteristics of bobbin

The quality of the spinning bobbin greatly affects winder operation (machine efficiency and work efficiency). In addition to full control over the spinning process, which is of course important, the preferred shape for spinning bobbins for use with this machine is shown below.

[Recommended bobbin dimensions]d3 ≥ d2d1 = d2 + 6 mmd2 = 14 - 32 mma = 12 mm (minimum)b = 10 mm (minimum)L = 180 mm - 280 mmD = 34 mm - 75 mmH = 1.2 × D

Take-up TubeTake-up Tube

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.

θ .................................................................................3° 15’ to 5° 57’L .................................................................................170 to 178 (±1) mmt ..................................................................................2 mm or moreFluctuation at smaller diameter side at part A ............0.2 mm or lessResistance to the force from F ...................................20 kg or moreø D and ø d eccentricity .............................................Noneø d and ø 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 WindingRibbon 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 ø 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)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 ShapePoor Winding ShapeCause Action

[1] Bulge winding

The internal compression is increased as the winding diameter is increased due to the increase in the contact pressure of the package on the drum or to the increased density of the yarn. Thus, the internal yarn layers buckle. This occurs with coarse yarn and two-ply yarn.(1)Winding angle is too large.(2)Winding tension is excessive.(3) Contact pressure is too high.

(1) Lower the number of drumwind (from 2W to 1.5W)(2) Tension release is necessary for coarse yarn or bulky yarn.(3) To reduce contact pressure, a pressure reducer is necessary.

[2] Wrinkles This is caused by short traverse at the start of winding, reduced tension by slipping, and also by the bulge winding.(1) Inadequate tension and contact pressure.(2) Deflection of take-up tube center.(3) Poor adjustment of contact surfaces of take-up tube and drum.(4) Excessive application of increase.

(1) Improve the tension and contact pressure.(2) Remove defective take-up tubes.(3) Correct the small diameter driving of take-up tubes for paired drums.

Cause Action[3] Scramble (1) Drum does not stop at yarn

breakage.(2) Joining motions repeats several times.(3) Suction mouth comes in contact with package.(4) Contact pressure is too low.(5) Ribbon comes off.

(1) Replace the yarn clearer. Check MS2.(2) Check the joining motion and yarn path. Also check the splicer.(3) Adjust the suction mouth stopper.

[4] Stitch The yarn is dropped off the edge of package.(1) Inadequate tension or variation of tension.(2) Flaw near the drum nose.(3) Improper rotation of cradle bearing center.(4) Loose cradle.(5) Improper position of drum tocone holder.(6) By ribbon winding.(7) By sloughing.(8) By low humidity (hemp, acrylic)

1) Set the tension properly.(8 to 12% of single yarn strength)(2) Correct the flaw on the drum.(3) Replace the cradle bearing.(4) Correct the loose cradle.(5) Adjust the cradle.(7) Increase the humidity to 60%or more.

Cause Action[5] End missing At the winding end of spinning

bobbin or at yarn breakage, yarn end is wound on the either end of the take-up tube or wound into the package layer.(1) Improper gap between the drum cover and the package.(2) Excessive sloughing.(3) Excessive surface cut of spinning bobbin.(4) Winding speed not suited tospinning bobbin building.

1. Increase the humidity (60% or more).2. Remove the cause for sloughing.3. Improve the spinningprocess.4. Improve the spinning bobbin building (spinning process) or lower the winding speed.

[6] Ribbon winding

This is most likely to occur when the ratio of the drum diameter and package diameter is an integer.With rotary traverse type of winder, it is not possible to completely prevent ribbon winding, but dispersing ispossible.(1) Improper setting of disturbance.(2) Excessive contact pressure.(3) Improper rotation of cradle.

(1) Change the disturbance setting. (2) Lower the contact pressure.(3) Replace the bearing of cradle if the rotation is heavy.

Cause Action[7]Stepped winding

(1) Flaw on drum.(2) Flaw on drum cover.(3) Low tension.(4) Disengaged yarn from the yarn path after machine cleaning.

(1) (2)Check the flaw and repair by sanding.(3) Increase the tension.(4) Be careful not to blow the yarn when cleaning with air.

[8] Pattern winding

(1) Improper guiding of yarn tothe tensor.(2) Foreign substance on tensor.(3) Excessive variation inunwinding tension due to improper forming of spinningbobbin.

1) Check and correct any flaw on yarn guide.(2) Clean the tensor.(3) Check and improve the spinning bobbin building.

(4) Low increase.(5) Bal-Con adjustment problem.(6) Low tension.

4) Improve the increase.(5) Adjust the Bal-Con.(6) Increase the tension.

Cause Action[9] Saddle back package

(1) Over tension.(2) Low contact pressure.(3) Low increase.

(1) Lower the tension.(2) Increase the contactpressure.(3) Improve the increase.

[10] Swelled package

(1) No tension is applied.• Improper guiding of yarn to tensor.• Foreign substance staying on tensor.(2) By ribbon winding.

• Poor return of tensorcutter.• Clean tensor.

QQUERIES……..?UERIES……..?