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Yarn Preparation (Winding)

Process/processes of preparing the yarn produced on the
spinning machine to meet the requirements of subsequent
processes, such as weaving, knitting and yarn dyeing
Clearing, winding and waxing are usually performed on
one machine: WINDER
Objecti ves of yarn preparation
Clearing: fault removal
Winding: transferring yarn from one package form to another
Yarn treatments: e.g. waxing, steaming and conditioning
Warping: preparing the warp package (beam)
Sizing: mainly for preparing the warp for weaving
Yarn must not be damaged during winding
Winding requirements
Yarn fault must be reduced to the required level
Yarn tension must be appropriate and as
uniform as possible
Package size, shape, build must meet the
requirements of the next process
Package types
Cylindrical
Cheese (with / without flange)
Pineapple cheese
Pirn
2
Cone
Package requirements
Size
Density
Stability
Unwinding performance
Package Build
Parallel build
High density
Unwinding is restricted
Flange is often required
Low stability
Parallel Built Package
With Taper (Roving)
Cross wound (quick traverse)
Lower density
Better stability
Large fluctuation of unwinding tension
Compromise of density and ease of withdraw
(shorter traverse length)
Chase build (progressi ve conical traverse)
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Main layer
(slow lifting of ring rail)
Ring Package (Cop)
Tube
Cross layer
(fast descending)
Package building
motion
tD
D
Basic theory of winding
Angle of wind (two definitions)
Angle between yarn and package axis
Angle between yarn and any plane perpendicular to
the package axis
u
u
Vt
DpNp
Vt
Vp t
u = = Tan
Winding speed
u
Np
Vp
Vt
Vw
Dp
2 2
Vt Vp Vw + =
Angle between yarn and package axis
Effects of Angle of Wind
Package Density
Minimum Density at 45
o
Maximum Density at 90
o
(Parallel Wound)
Effects of Angle of Wind
Package Density
Package Stability
Maximum ~ 80
o
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If winding angle is too large,
coil pitch can be too small on tube (small D),
increasing risk of yarn entanglement
C
o
il p
it
c
h
Effects of Angle of Wind
Package Density
Package Stability
Traverse speed
Power consumption
Acceleration force on yarn guide
Normal range: 70
o
~80
o
(limit depends on yarn type and winding speed)
Vt
Vp
= u Tan
Number of yarn coils wound on package during one
single traverse (from one end of package to other end)
Wind
Number of yarn coils wound per complete traverse
cycle (from one end of package to other end and back)
Traverse ratio
It is twice the wind
Nt = Vt / 2Lt
Lt = traverse length
Vt = traverse speed (ignoring reversal effects)
If
Number of double traverses per minute
(traverse rate):
Lt
Traverse ratio Tr = Np/Nt
Traverse Ratio:
Number of Yarn Coils per Cycle (Double Traverse)
5
Tr = 10
Tr = 5
Patterning (Ribboning)
Repeated winding of yarn at exactly the same
place on the package during successi ve
double traverses
Patterning causes
Poor unwinding performance
Uneven colour in dyeing
Traverse Rati o=3 Traverse Rati o=2.5
The yarn will return to its starting point
after n double traverses
With a traverse ratio of w +m/n
w, m and n are integers
m < n
m and n have no common factors
5-1/15 5-1/20 5-1/37 5-1/43 5-1/68 5-1/1000 5+77/10000
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Traverse method
Reciprocating yarn guide
Traverse method
Reciprocating yarn guide
Characteristics
Speed limited by inertia
Flexible in package formation
No appreciable twist displacement
Grooved Drum
Traverse method
Mainly used for spun yarns
Grooved drum
Characteristics
Usually also act as package drive roller
No inertia problems
Lower energy consumption
Less maintenance cost
More twist displacement
More yarn abrasion by drum
Higher tension is required
Traverse method
Rotating blades
Traverse method
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Not widely used
Rotating blades
Characteristics
No inertia problem
Flexible package formation
Blades can cause yarn damage
Blades may lose control of yarn at
reversal points, causing traverse
length variation
Traverse method
Package drive
Friction drum
Not suitable for yarns with
low abrasion resistance
Direct drive
Constant rotational speed
(wide application)
Constant surface speed
(expensive)
Traverse ratio decreases
Random winding
Package surface speed (Vp)
and
Traverse speed (Vt or Nt)
are constant
Since tanu = Vp / Vt
Angle of wind is constant
But Np = Vp / tDp
Dp increases
Np decreases
During winding
Tr = Np / Nt
Tr =Np/Nt =Vp/tDpNt
Smaller Dp Faster Tr changes
But package diameter Dp increases
So package surface speed
Vp=tDpNp increases
And
tan u = Vp/Vt increases
Precision Winding
Package rotational speed (Np)
And traverse rate (Nt) are constant
Tr = Np/Nt
Traverse ratio is constant
So winding angle increases
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Combination of precision winding and random winding
Some general aspects of precision winding
Package drive (constant Np)
Patterning (avoided by suitable traverse ratio)
Limited package diameter (winding angle/speed)
Variable production rate
Close-winding and open-winding
Close Wind Open Wind
The magnitude of the gain determines how close to each
other yarn coils from successive double traverses will be
Precision Winding
Gain
If the traverse ratio is w + z
where w is an integer
Yarn coil from successive layers
will be displaced by z revolutions
z is the gain
Gain can be positive or negative
tDp
Lt
y
Dp/2
y=tzDp
y=d/cosu
Traverse Ratio=2+z
y
u
z
d
u
u y
d
Z = y/(tDp) = d/(tDpCosu)
For close winding:
Yarn diameter (count, twist, fibre type)
Package diameter
Winding angle
The gain required for close winding depends on
Z = d/(tDpCosu)
The loss of traverse length at high
package speeds
Limits of winding speed
The inertia of the yarn guide (Nt ~ 450 d.t./min)
The traverse ratio (Tr = Np/Nt)
The angle of wind (70
o
~ 80
o
)
The textile limit imposed by the yarn
(~1200 m/min for spun yarns)
Winder speed can be much higher
Vt
Vp
= u Tan
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Short term tension variation
Cheese: length of thread path varies from
the middle to the ends of package, causing
speed variation and tension variation
Cone: yarn speed varies along package length
Short term tension variation
Cheese: length of thread path varies from
the middle to the ends of package, causing
speed variation and tension variation
Cone: yarn speed varies along package length
Short term tension compensators
Short term tension variation
Cheese: length of thread path varies from
the middle to the ends of package, causing
speed variation and tension variation
Tension Control
Yarn tension must be controlled within limits
for good package formation, correct package
density and minimum yarn damage
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Over-end Unwinding
Unwinding tension
Adds twist
Extra tension is usually applied
Less affected by yarn speed variation
Tension varies as balloon height changes
Friction (low speed: yarn sliding on the surfaces
of tube and package)
Balloon (high speed)
Stationary package
Over-end
Unwinding tension
Side Unwinding
Unwinding tension
Only applicable to high tension winding (e.g. coarse industrial
yarn) and low speed negative let-off systems (e.g. warp supply)
Rotating package
Rotational speed must vary to maintain
constant yarn speed
Positive driven
Negative let-off
Inertia changes with package weight
Acceleration and deceleration cause large tension fluctuation
Package must be retarded
on package surface
on spindle
Package growing at high speed
Yarn tension can not be kept low and regular at high speeds
Side Unwinding
Inexpensive
Tensioner
Easy to thread
Easy to adjust
Yarn tension within specified limits
Unaffected by yarn lubricants, loose fibres and fly
Easy adjustment and self-compensating for wear
Not affecting yarn twist distribution
Device to Increase Yarn Tension During Winding
Requirements
T1
T2
Yarn path
direction
u1
u2
T3


1 1
1 2
u q
e T T =

=
u q
e T T
in out
2 2
2 3
u q
e T T =
2 2 1 1
1
u q u q
e e T =
) (
1
2 1
u u q +
= e T
Tensioning devi ces
a) Friction rods: multiplicative
Magnifies tension fluctuations
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=
u q
e T T
in out
Example
T
in
= 101 g
10 =

u q
e
T
out
= 10010 g
T2 T1
P
T2 T1
P
T2 = T1+qP
T2 = T1+2qP
b) Tension roller and plate
c) Two tension plates
(b) and (c) are additive
Influenced by
Can cause twist redistribution
and twist variation
dirt accumulation
localised wear
T2 = T1+qP
Example
T
1
= 101 g
T
2
= 1001 g
qP = 90 g
Constant Torque
Pulley Rotates with Yarn
No Slippage
Pulley tensioner
pulley with constant torque
yarn pulls it around without slippage
P
Disk tensioner
combination of additive &
multiplicative principles
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T1
T2
Tension Compensator
Provide constant winding tension,
independent of unwinding tension