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15T404 Fabric Manufacture I: Warp Winding

The document discusses various aspects of warp winding and winding machines. It describes objectives of winding, types of wound packages, winding machines and their components, principles of yarn tensioning and measurement of unevenness. It also discusses splicing, anti-patterning systems like Propack and TIRAC, and issues like patterning.

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Prabhakaran J
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0% found this document useful (0 votes)
73 views45 pages

15T404 Fabric Manufacture I: Warp Winding

The document discusses various aspects of warp winding and winding machines. It describes objectives of winding, types of wound packages, winding machines and their components, principles of yarn tensioning and measurement of unevenness. It also discusses splicing, anti-patterning systems like Propack and TIRAC, and issues like patterning.

Uploaded by

Prabhakaran J
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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15T404 Fabric Manufacture I

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

• Reciprocating a yarn guide along the length of


a package, commonly termed reciprocating
traverse
• Guiding the yarn by helical grooves designed
on the surface of a rotating drum, commonly
termed rotary traverse
• Guiding the yarn by a series of rotating
blades, termed multipede traverse
Principle of multipede traverse. All
pairs of blades in overlapped state at
extreme left reversal
point of traverse.
Two types of winding principles
• Drum-driven or random winders
• Spindle-driven or precision winders
Drum-driven wider

The package is driven by a cylinder by surface or frictional contact . Traverse of yarn is


given either by the grooves cut on the drum or by a reciprocating guide. In case of
grooved drum, the drum performs the dual functions of rotating the package by
surface contact and performing the traverse. However, when plain drums are used,
it just rotates the package and traverse is performed by reciprocating guide

Types of drum-driven winder (a: grooved


drum, b: plain drum)
Two types of spindle-driven winders

• Constant r.p.m. spindle winders


• Variable r.p.m. spindle winders
Important definitions
(Wind, wind ratio, angle of wind, Coil angle)

• Wind: It is the number of revolutions made by the package


(i.e. number of coils wound on the package) during the
time taken by the yarn guide to make a traverse in one
direction (say from left to right) across the package.
• Traverse ratio or wind ratio or wind per double traverse: It
is the number of revolutions made by the package (i.e.
number of coils wound on the package) during the time
taken by the yarn guide to make a to and fro traverse. This
to and fro traverses of the yarn guide from left to right and
back from right to left is known as double traverse.
Traverse ratio= 2× Wind
Angle of wind ( θ ) : It is the angle made by the yarn with the sides of the package (Figure 2.3). If surface
and traverse speeds are Vs and Vt respectively, then

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°.

Figure 2.3: Angle of wind and coil angle

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.

• According to working principle


1. Capstan tensioner
2. Additive tensioner
3. Combined tensioner
• According to type of working member acting on the yarn
1. Washer type tensioner
2. Disc type tensioner
3. Comb type tensioner
4. Roller type tensioner
5. Ball type tensioner
Principle of capacitance based unevenness measurement
Principle of optical based
measurement
2.9 Splicing
• Splicing is the process by which the two ends of yarns are joined. In most of
the machines dealing with spun yarns, pneumatic splicers are used. Robotic
arms aided with air suction bring two ends of the yarns inside the splicing
chamber. Then compressed air is jetted to create turbulence inside the
chamber so that the yarn is untwisted. Then some fibres are removed from
the yarn ends to create wedge shape. Jetting of compressed air is done
again to twist the two superimposed ends of yarns . Splicing introduces a
less severe fault in the yarn and the appearance of spliced portion of yarn is
checked by making the yarn appearance board. The quality of spliced yarn
is checked by using the parameters like retained splice strength and splice
breaking ratio as defined below:
• Higher retained splice strength (85-90%) and lower splice breaking ratio
imply good splicing performance.
Figure 2.45: Steps of yarn splicing

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

Package with propack Elimination 


of pattern zones 
Fig-2
Source: Schlafhorst/Saurer Group 
Technical Leaflet
Semi-conductor device (TIRAC)
• Semi-conductor device (TIRAC) is used on all models of Muratec Mach
Coner Automatic winder for pattern breaking. The device is illustrated in
Fig.3. Anti-patterning effect is achieved by means of DIAL setting for ON
and OFF durations of the drum motor. Thus the speed change cycle is
adjusted. As the drum and therefore, the package is constantly being
accelerated and decelerated, the ratios of their speeds never reach critical
value to produce patterning.

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

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