15T404 Fabric Manufacture I: Warp Winding
15T404 Fabric Manufacture I: Warp Winding
Warp winding
Objectives of Winding
To wrap the forming yarn on a package in a systematic
manner or to transfer yarn from one supply package to
another in such a way that the latter is adequately compact
and usable for the subsequent operations.
To remove the objectionable faults present in original yarns.
Types of wound packages
Types of winding machine
Method of withdrawal from supply package
• Side withdrawal
• Over-end withdrawal
• Side withdrawal is preferable for flanged packages as the yarn does not touch with
the flanges. The package has to rotate during the yarn withdrawal. However, for
ringframe bobbins, over end withdrawal is performed by keeping the package in
almost upright conditions. As one coil comes out from the ringframe bobbin, one
twist is either added or subtracted from parent yarn depending on direction of
twist in the yarn.
Yarn traverse on package can be carried out by
Coil angle ( α ) : It is the angle made by the yarn with the axis of the package . The coil angle and angle of
wind are complementary angles as they add up to 90°.
The net winding speed can be obtained by the resultant vector of surface speed (Vs) and traverse speed
(Vt ).
Types of tensioning devices
The primary objective of yarn tensioning is to build a package with adequate compactness.
The performance of a splicer is also evaluated by the parameters like clearing efficiency and
knot factor. As knotting device is not used in modern winders like Autoconer, the term knot
factor may be replaced with splice factor. Higher clearing efficiency and lower splice factor (close
to 1) signifies desirable performance of a splicer.
Propack® system
• Propack® is a new cradle anti-patterning system incorporated by Schlafhorst in the automatic package winding machine
Autoconer 338 launched in 1997. The entire product range has been available since ITMA Paris in 1999. As already
mentioned patterning occurs when the number of coils laid on the package per double traverse is a whole number. In
other words, pattern zone is reached when the ratio between drum speed and package speed reaches a critical value.
• The ratios between the drum and the package speeds are constantly determined by the highly precise winding unit
computer of the propack system illustrated in Fig. 1.
• As soon as the critical speed ratio which produces patterning is about to reach the propack system reduces the pressure
on the cradle by a pre-determined amount. Thus the package runs more slowly at a speed below the critical patterning
speed till the package diameter is adjusted to a value above the pattern zone when the propack® cradle anti-patterning
system is turned off.
• The anti-patterning effect achieved by the propack® system is illustrated in Fig.2.
• The propack® packages are recommended for use in technologically demanding applications. The requirements of
standard applications can be met by packages, produced on winding machines fitted with conventional electronic anti-
patterning devices.
• The problem of yarn bulging out on the package flanks is encountered in the case of winding elastic yarns such as lycra
yarns. This problem arises because yarn is slightly tensioned during winding and tends to contract back to its original
position. The outer layers exert pressure on the inner yarn layers which bulge out on the package flanks. Such packages
create problems in subsequent processes of twisting and dyeing.
• Schlafhorst has solved this problem by combining Autotense and propack® systems in the Variopack FX system for use in
winding of elastic yarns. Some of the other sophisticated devices, which make Autoconer 338 a state-of-the-art machine,
are ATT (Auto Torque Transmission), balloon controller, Autospeed control system with thermo-sensor, vacuum controlled
suction plant with AVC system sensor monitoring of the winding process with short piecing cycles.
Package without anti-patterning extensive pattern
zones and pronounced bands
Semi-Conductor Device
Source: Muratec technical
leaflet
Patterning
• If the traverse ratio (wind per double traverse) value is an integer, then the yarn
comes back to the same position on the package surface after one double traverse.
This happens because the diameter of the yarn is minuscule and thus one double
traverse does not cause significant increase in package diameter. Therefore, in the
next double traverse, the yarn is laid just over the yarn which was laid in the previous
double traverse. As a result, a ribbon develops in the package. This problem is known
as patterning problem.
• In case of drum-driven winders, the traverse ratio value reduces with the increase of
package diameter. When, the value becomes integer, the package becomes
susceptible to patterning.
Precision Winder