Winding

Winding is the process of transferring yarn or thread from one type of package to another to
facilitate subsequent processing. It may be electrical or mechanical.
Warp- Cone, cheese, flanged bobbin.
Weft- Pirn, cop.
Objectives
 To transfer yarn from one package to another suitable package that facilitate weaving
process.
 To remove yarn faults like neps, slubs and foreign matters.
 To clean yarn.
 To improve the quality of yarn.
 To store the yarn.

Ring Cops Cone

Yarn weight normally 50 gm to 62 gm

Other Winding Packages

 Fig: Winding Diagram

Types of Winding
According to the build of the package
 Cone winding machine.
 Cheese winding machine.
 Pirn winding machine.
 Cop winding machine.
 Flange bobbin winding machine.
According to density
 Precision winding machine.
 Non precision winding machine.
According to methods of drive
 Direct drive.
 Indirect drive.
According to the build of the package
 Parallel winding.
 Near parallel winding.
 Cross winding.
According to the features of automation
 Conventional winding.
 Modern winding.

Advantage of Parallel Winding

1. In this package, so many yarns can be wound at a time.
2. No change of twist during winding.
3. The package is stable here.
4. There is a possibility of side with drawl here.
5. Yarn density is more.
6. Traversing mechanism is not needed.
Disadvantages of Parallel Winding
1. Need flanged package.
2. Over-end withdrawl is not possible here.
3. Needed separate mechanism for yarn unwinding.
Advantages of Cross Winding
1. Over with drawl is possible here.
1. Stability of yarn package.
2. Flanged is not needed here.
Disadvantages of Cross Winding
1. Yarn quality is less here.
2. Yarn twist is changed during winding.
3. Traversing mechanism is required here.
Difference
Precision Winding Non Precision Winding
Yarn density in winding package is high Yarn density in winding package is lower
Winding package is more compact Winding package is less compact and soft
Angle of winding is near 90° or 90° Angle of winding is less than 80°
Yarn tension in package is comparatively Yarn tension in package is comparatively
high. less
Wound coil is laid near parallel or parallel to Wound coil is laid in cross wise.
each other.
Flanged bobbin is used here Flanged bobbin is not used here
Lower durability of the winding package Higher durability of the winding package
One or more yarn can be wound in package Single yarn is wound here.
Lower stability Higher stability
Package is hard Package is soft
Unwinding rate is lower Unwinding rate is higher
Unwinding process is harder Unwinding process is easy
No air gaps is found here Air gaps is found here
More time needed in unwinding process Less time needed in unwinding
Difficult to dye Easy to dye
Process is less hairy Process is more hairy

Requirements of winding
• The fault level in the yarn must be reduced to an acceptable level.
• The yarn must not be damaged in any way in the winding process.
• The yarn must be wound in such a way as to permit unwinding in the following process
with a minimum of difficulty at the required speeds.
• The package size, shape and build must be the most technologically suitable for the
particular end use.
• The package size should be controlled to meet the particular economic requirements.
• The winding operation must be geared to give the best possible economic performance
of the whole process of fabric manufacture.

Soft Winding
The yarn is winded at low degree angle that’s why the package will be soft is known as soft
winding.
In yarn dyeing process, soft winding section is the first section. Here yarns are transferred
from paper cone to perforated steel tube or plastic tube to facilitate the dyeing process. It is
one type of rewinding process. Different modern winding machineries are used for winding
function. Here different parameter is maintained which effect in the dyeing process directly.
Objectives:
 To make soft package (Density should lies between 0.300-0.350 gm/cc).
 To transfer yarn from paper cone steel or plastic tube.
 To reduce the density of the package.
 To remove unwanted material from the package
 To make free the cone from yarn to facilitate the next process.

Calculation

Volume of the package V = π (r12 – r22) × h CC

When package are too soft then liquor flowing through it, will find the course of least
resistance and cause channeling, which leaves some parts of the package relatively lighter or
undyed. If the packages are wound too hard, a point can be reached where the flow of liquor
is impeded to such an extent that poor dyeing or none may occur.
Tensioning device:
The device which is used to give the yarn proper tension during winding is called tensioning
device.

Importance or effect of tensioning device:

Too high tension:
* Can damage the yarn.
* Breakage rate may greater.
* Elongation property of yarn may change.
* Weaken the thin places of yarn.
* Hard package.
Too low tension:
* Permit unstable or loose package.
* Slough off happened during unwinding.

For man made filament yarn:

* Can cause molecules changed.
* Variation in color shading.

Various types of tension device (According to working principle):

1. Capstan method:
It is a simple form of yarn tensioner. It works by merely deflection the yarn around the fixed
parts. This induces a capstan effect.

Output tension= input tension X eµθ

Or, T2=T1 X eµθ
Where,
T1= input tension,
T2= output tension θ1 θ2 θ3
μ= coefficient of friction between yarn & post.
θ= Angle of lap (in radian) = θ1+θ2+θ3
e= 2.718

2. Additive method:
In this device a dead load or spring is used to give a fixed increment of tension.
Here, T2=T1 + 2μF
Where, T1= input tension
T2= output tension
μ= coefficient of friction
between yarn & post
F= applied force.
3. Combined method:
Combined system of capstan & additive tensioner. The device permits the tension level to be
raised to any desired extent, but it does not permit a reduction in tension.
Here, ,T2=T1eµθ+ T1 + 2μF
Where, T1= input tension
T2= output tension
μ= coefficient of friction between yarn & post.
θ= Angle of lap (in radian) = θ1+θ2+θ3
e= 2.718

4. Automatic Method:
Yarn tension is controlled automatically. There is a lever which one side contain spring
loaded disc & another side contain applied load. If yarn tension is very high then applied
load decreased & spring loaded device control tension moving upwards. Again if yarn
tension is low then applied load increased & spring loaded disc back its proper level
(downwards) & thus control the tension.

Factor influences for selection of tensioner

* It must not damage the yarn.
* It must not introduce differences in twist.
* It must be easily threaded.
* It must neither introduce nor magnify tension variation.
* It must be easily adjustable.
* It must not encourage the collection of dirt & lint.
* It must be capable of easy cleaning.
* Smooth operating surfaces.
* It must be cheap.
* It must be simple in design & operation.
Yarn Guides:
In winding & unwinding it is necessary to control the yarn path.
Types of Yarn guides:
Generally there are two types of yarn guides:-
1. A yarn end is required for threading:
* Takes extra time for threading.
* Yarn passed through the guide hole.

2. A yarn end is not required for threading:

* Treading is very easy.
* Operations time less.

Yarn Clearer:
To remove the following faults of yarn in order to increase the yarn quality & weaving
efficiency.
Faults removed by yarn clearer:-
* Thick & thin places in the yarn.
* Slubs & neps.
* Loose fibres.
* Foreign materials.
Types of yarn clearer:
Mechanical type:
1. Ordinary metal sheet type.
2. Comb type.
3. Ordinary metal slit type.
4. Blade type (mostly used).
5. Disc type.
6. V-type.
Principle
A mechanical clearer maybe as simple as two parallel blades. The distance between the
blades is adjustable to allow only a predetermined yarn diameter to pass through. A thicker
spot on the yarn (slub) will cause the tension on the yarn to build up and eventually break the
yarn. Consequently, this type of device can only detect thick places in the yarn.
Electronic type:
1. Capacitance type
2. Solar type.
Principle
If a yarn (4) is brought into this field, the capacitance of the measuring condenser is changed.
From this change, an electrical signal, the yarn signal is (5) is derived. The change in the
capacitance depends, besides of the mass of the yarn and of the dielectric constant of the fibre
material is used, on the moisture content of the yarn.

Optical yarn clearer

Uses of yarn clearer:

1. Different types of winding machine.
2. Before the beaming of warp or weavers beam.

Yarn withdrawal or Unwinding:

Unwinding process of yarn from a package is called withdrawal of yarn.
There are two types of withdrawal:
1. Sideway withdrawal.
2. Overend withdrawal.

Sideway withdrawal.
1. Package rotates.
3. Yarn twist become unchanged.
4. No balloon formation.
5. Slow process.

Overend withdrawal.
1. Stationary package.
3. Yarn twist may changed.
4. Balloon formed during withdrawal.
5. High speed process.

Ballooning:
The appearance of the curved paths of running yarns during spinning, winding on or while
they are being withdrawal over-end from packages under appropriate yarn winding
conditions.
Balloon size and shape depend on the following factors:

1. Count of the yarn: Finer the count - higher the balloon size.
Coarser the count - lower the balloon size.

2. Winding and unwinding speed:

Higher the speed - higher the balloon size.

3. Size and shape of the package:

Larger the package - greater the balloon.

4. Position of the guide:

Greater distance - higher the balloon size.

5. Lift of the package:

Larger package - greater the balloon size.

Auxiliary Function in Winding:

The auxiliary function may be performed manually or automatically.
The auxiliary function includes:
1. Creeling.
2. Piecing.
3. Doffing.

# Creeling:
This is transfer operation. Transfer the empty packages & placing the full packages is called
creeling.

# Piecing:
Piecing is the finding & connecting of ends of yarn on the package.
The connecting ends can be made by knotting, adhesion or welding.

# Doffing:
Doffing is full removal of full package by empty package in delivery side.

Methods of Driving:
1. Surface contact drivrng or indirect driving.
2. Directly package driving at constant r.p.m.
3. Directly package driving at variable r.p.m.
Surface contact drivrng or indirect driving:
Surface contact produces frictional force to rotate the package. Diameter of the package is
inversely proportional to the r.p.m. of the bobbin & the drum gets drive from a motor.

Directly package driving at constant r.p.m:

Package is placed up in a spindle which gets drive. Here packages r.p.m are constant. So
diameter of package is directly proportional to yarn take up rate. For this reason yarn gets
tension & there occurs always breakage tendency. Yarn is not twisted in this method.

Directly package driving at variable r.p.m:

In this method the yarn package is driven directly at variable speed, to give constant yarn
take up speed, it is necessary to cause the rotational speed to vary inversely with the
package diameter.
TRAVERSE MOTION:
When a dynamic part of a machine moves in to & fro motion or left to right and right to left,
then this movement is called traverse motion.

Traverse method are mainly two types:

1. Reciprocating motion &
2. Rotating motion.
Winding Efficiency
Winding Efficiency =

Actual Production < Calculated Production.

Efficiency Loss =

Winding Faults
 Faulty shape of package,
 Jail formation or stitching,
 Formation of ribbon,
 Soft package,
  Collapsed cone,
 Bell shaped cone,
 Nose bulging,
 Ring shaped cone,
 Imperfect winding speed,
 Tight bobbin,
 Patches formation on the yarn,
 Two end winding,
 Mixing of yarns of different linear density,
 Wild yarn,
 Imperfect shape of winding packages,
 Less removal of neps, slubs, dirt and loose fibres,
 Excessive knot in the yarn,
 Excessive full bobbin,
 Variation of tension,
 Knots with long tail or slack knots,
 Overlapping,
 Snarl,
 Entanglement of yarn.

Ribboning or patterning
A ribbon like structure is formed on the circumference of the cone.
Sources
- Restriction in the rotation of the winding spindle
- Improper setting of cone holders
Corrective action
- Cone winders are to be overhauled periodically
- Accurate set-up of cone holder.
2. Jail formation or stitching:
This is due to improper laying out of ends onto the cone.
- Cone holders that are improperly set and are vibrating
- Tension brackets misaligned with winding drum
- Wrapping of coils of thread around the bottom of cone holder.
- Traverse restrictors fixed at incorrect position
Corrective action
- Overhauling of cone winders to be done time to time
- Accurate set-up of cone holder.

3. Ring shaped cone

Sources
- Incorrect setting of cone holder
- Wrong placement of tensioners in the tensioning assembly
- Traverse of yarn affected due to defects in the grooves of the drum
Corrective measures
- Due replacement of defective drums and stop motion wires to be ensured
- Periodic inspection of cone holder settings and tension assembly to be carried out

4. Bell shaped cone

The cones are tightly built at centre and appear in the shape of a bell.
Sources
- The tension of yarn is high during winding
- Improper setting of cone holders with winding drum
- Paper cones being damaged at the middle

5. Nose bulging
It results in bulging of bunches of yarn at the nose of the cones.
This leads to slough off during warping.
Sources
- Setting of cone holders to winding drum is incorrect
- Periodical inspection of settings in machines
Corrective actions
- Avoiding use of damaged paper cones
- Tenters to be instructed to adopt correct work practices

6. Collapsed cone
Sources
- Use of poor or damaged cones
- Poor system of material handling
- Maintaining non optimum unwinding tension
Corrective actions
- Tenters to be trained on correct work practices
- Proper material handling devices such as cone transport trolleys to be used
- Cone inserts to be used for paper cones
7. Imperfect winding speed:
Remedies:
Correct winding speed should be there.
8. Tight bobbin:
Remedies:
Bobbin should be perfect.
9. Mixing of yarns of different linear density:
Remedies:
Linear density of mixed yarn should be same.
10. Less removal of neps, slubs, dirt and loose fibres:
Remedies:
Should be free from slubs, neps and loose fibres.
11. Excessive full bobbin:
Remedies:
Yarn should be wound at a definite length.
12. Variation of tension:
Remedies:
Tension have to same throughout the total winding process.