Limitations of ring spinning Technological
Yarn tension (traveller drag, balloon) Traveller speed Heat Draft system
Insert Twist by Rotating Yarn?
Economic
Large package size required (fewer knots, fewer replacements) but larger package requires more power to drive and faster traveller speed Cause of Problem: Twist Insertion Requires Package Rotation
Static Yarn
Twisting
Moving Yarn False Twist No Twist
Twisting
Open-End (Break) Spinning Principle
Advantage of Open End Spinning
Smaller mass involved in twist insertion higher speed Break in Fibre Flow No spinning balloon lower yarn tension Twisting Package formation independent from twisting larger size, choice of form, reduced winding
Fibre Transfer Fibre Supply
Winding
Spinning direct from sliver no roving
Brief History of Open-end Spinning Development 1876 J Hibry
USP173290 J Hibry 8 Feb. 1876
Brief History of Open-end Spinning Development 1876, J Hibry 1937, Svend Ejnar Berthelsen
Svend Ejnar Berthelsen GB477259 24 Dec. 1937
Brief History of Open-end Spinning Development 1876, J Hibry 1937, Svend Ejnar Berthelsen 1955, ITMA Brussels, Spinnbaus Meimberg eMKa-Spinner
Svend Ejnar Berthelsen GB477259 24 Dec. 1937
USP3119223 Julius Meimberg 2 July 1956
USP3119223 Julius Meimberg 2 July 1956
Brief History of Open-end Spinning Development 1876, J Hibry 1937, Svend Ejnar Berthelsen 1955, ITMA Brussels, Spinnbaus Meimberg eMKa-Spinner 1960s, Intensive R/D in many countries
Brief History of Open-end Spinning Development 1876, J Hibry 1937, Svend Ejnar Berthelsen 1955, ITMA Brussels, Spinnbaus Meimberg eMKa-Spinner 1960s, Intensive R/D in many countries 1965, KS 200, the first machine with drafting rollers exhibited in Czechoslovakia 1966, BD200 installed in factory 1967, ITMA Basel, Switzerland, Elitexs BD200, 30,000 rpm
BD200b
Brief History of Open-end Spinning Development 1876, J Hibry 1937, Svend Ejnar Berthelsen 1955, ITMA Brussels, Spinnbaus Meimberg eMKa-Spinner 1960s, Intensive R/D in many countries
Common requirements of open-end spinning Fibre separation device Means of fibre transportation Device for collecting separated fibres
1965, KS 200, the first machine with drafting rollers exhibited in Czechoslovakia 1966, BD200 installed in factory 1967, ITMA Basel, Switzerland, Elitexs BD200, 30,000 rpm 1971, ITMA Paris, wide spread commercial introduction 2003 8m rotors 174.5 m ring
Device for rotating open-end of yarn (twisting device) Yarn take-off and package build mechanism Key feature of open-end spinning: Separation of twisting from winding, but continuous operation
Critical point: yarn property Most successful system: rotor
Rotor Spinning Principle
Rotation of Yarn Arm Inserts Twist in Yarn
Air Exit Rotor
Yarn Delivery
Nozzle Fibre Transport Channel
Feed Roller Opening Roller Feed Shoe
Sliver
Trash
Opening Roller
Rotor
Nozzle
Example of Fibre Mass Attenuation
Feed Roller Opening Roller Exit of Fibre Transport Tube Rotor Groove Yarn Withdraw Point
Fibre Speed (m/s)
0.015
30
100
200
2.5
Draft
2000
1/80
No. of Fibres In Cross Section
20,000
10
1.5
120
Yarn Arm
Fibre Transport Channel
Twist in Yarn: t= Ny Vd Rotor Rotation Nr (rpm)
Yarn Twist
Yarn Arm Rotation Ny (rpm) Nozzle
t = Nr Vd
Back Doubling: t D
Vd = (Ny-Nr) D Vd Ny = Nr + D t= Nr Vd Nr Vd + 1
Yarn Peel-off Point Moving Relative to Rotor = Yarn Delivery Speed Vd (m/min)
Production rate (kg/h):
Vd
D Ignored
Nr Ny-Nr Rotor Diameter = D (m) Nr Vd D Nr D Vd tD
Vd
tex 1 60 E N 1000 1000
t=
Back Doubling:
Important Rotor Parameters
180 160 140
Thousand RPM
120 100 80 60 40 20 0 1967 1972 1977 1982 1987 1992 1997 2002 2007
Rotor Diameter D
Rotor Speed and Diameter Rotor Diameter D
160000
Smaller rotor Higher speed
120000 Max. RPM 80000 40000
Current minimum: 28 mm Must have sufficient size so that longest fibre does not form a complete loop
Minimum D > Staple Length
0 28 32 36 40 44 48 52 56 Rotor D (mm)
Important Rotor Parameters
Groove Angle
: 30-60o
Thicker yarn: Larger D &
Opening Roller Speed
Higher speed gives better fibre opening
Rotor Diameter D
: 12-50o Smaller for Higher Rotor Speed
If opening roller speed is too high, fibre striping by air may not be complete, leading to more yarn faults
Rotor Groove
Rotor Wall Angle
Optimum depends on fibre, yarn and rotor speed
Opening Roller Type Type of wire (pin or saw-tooth) Point density Working angle
Working angle
Pin Type
Saw-tooth Type
Rieter Opening Roller Wire
Draw-off Nozzle
Steel draw-off nozzle:
For man-made fibres and blends No static charging Lower surface nozzle temperature
Effects of Draw-off Nozzle surface
Grooved nozzle increases false twist, helps to spin yarns with lower machine twist (e.g. knitting yarns)
Ceramic draw-off nozzle:
More hard wearing, longer life
Yarn rolling against stationary nozzle surface Stationary Draw-off Nozzle Effects of Draw-off Nozzle surface
Grooved nozzle increases false twist, helps to spin yarns with lower machine twist (e.g. knitting yarns) Grooves disrupt fibres in yarn, increasing hairiness and yarn faults
False Twist in Yarn inside Rotor
Rotating Yarn Arm
Effects of Draw-off Nozzle surface
Grooved nozzle increases false twist, helps to spin yarns with lower machine twist (e.g. knitting yarns) Grooves disrupt fibres in yarn, increasing hairiness and yarn faults Higher false twist increase wrapper fibres during untwisting by nozzle
Ring Spinning and Rotor Spinning Comparison Yarn Formation
Fibre Disposition Fibre straightness/alignment
Wrapper fibres
Loose fibre disorientate & crimp in airflow
Fibre straightening and parallelization by drafting Fibre under tension through the process
Fibre hooks develop on Opening roller
Ring Spinning and Rotor Spinning Comparison Yarn Formation
Fibre Disposition
Wrapping of fibre forms when incoming fibre attached twisting yarn arm
Fibre straightness/alignment Wrapper fibres Fibre migration
Spinning Triangle
Front Drafting Rollers
Core Fibres Migrate outwards
Surface Fibres Under Higher Tension Migrate inwards
To spindle
Ring Spinning and Rotor Spinning Comparison Yarn Formation
Fibre Disposition Fibre straightness/alignment Wrapper fibres Fibre migration Twist structure
False twist depends on nozzle friction
Rotor Yarn Twist
Ring Yarn Twist
All fibres twisted at same time with same t
Yarn formed gradually from core outwards Highest tension
Fibres deposited first (towards the core) has higher twist Fibres are twisted under low tension: low fibre straightness Twist differential & wrapping fibres make twisting testing difficult
Fibres near core has lower twist angle & under lower tension
Ring Spinning and Rotor Spinning Comparison Yarn Formation
Fibre Disposition Fibre straightness/alignment Wrapper fibres Fibre migration Twist structure Yarn properties
Ring Spinning and Rotor Spinning Comparison Yarn Properties
Tensile properties Evenness Aesthetic properties Hairiness Abrasion resistance Others
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Ring Spinning and Rotor Spinning Comparison Ring Spinning and Rotor Spinning Comparison Raw material requirements Techno-economics
Investment Fixed costs
Fibre length Fibre fineness
Operating costs Raw materials/waste Maintenance
Fibre strength Effects of drawing Impurity content
Labour Energy Product value Application Fibre type Yarn type and end-use
Machine Example
Ring Spinning and Rotor Spinning Comparison Ring Spinning
Wider yarn count range Suitable for most fibre types Good yarn tensile, hand and aesthetic properties More preparatory processes Low speed High power requirement
Rieter R 40
Material cotton, man-made fibres and blends up to 60 mm Feed weight 7.00 to 2.5 ktex Draft 40 to 400 Yarn count 200 to 10 tex Twist 196 to 1500 T/m Package weight max. 6 kg (max. 350 mm ) Rotor 28, 30, 31, 33, 36, 37, 40, 41 46, 47, 48, 56, 57 mm
Small bobbin Opening rollers 64 mm High doffing frequency (lower efficiency/higher labour cost Draw-off nozzles ceramic in various designs
Rotor Spun Fancy Yarns Limited to fibre effects (mainly slubs) Variable motor driven sliver feed
Difficult to produce abrupt changes Minimum length D due to back-doubling
Rotor Spun Fancy Yarns Other developments
Special opening roller (using negative working angle for cotton so that fibres accumulate on roller and produce random bundles in yarn) (0.5-4 inch length slubs)
Multi-twist effects (altering yarn twist randomly) Cover yarns
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Core Yarn
Cover Yarn
Staple Yarn
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