SUSANTA SEKHAR DE, Assistant Professor, Department of Textile Technology, GCETTS (WB, INDIA)

CLASS Notes on Ring Spinning Technology (Part – II)

Rings & Travellers

Introduction

In most cases, the limit to productivity of the ring spinning machine is defined by the traveller in
interdependence with the ring, and yarn. It is very important for the technologist to understand this
and act on them to optimize the yarn production.

The following factors should be considered -

 materials of the ring traveller;

 surface characteristics;
 the forms of both elements( ring and traveller);
 wear resistance;
 smoothness of running;
 running-in conditions; and
 fibre lubrication.
SUSANTA SEKHAR DE, Assistant Professor, Department of Textile Technology, GCETTS (WB, INDIA)

The Form Of The Ring:

Basic Forms:
These are classified into:
A) Lubricated rings (in woollen and worsted spinning),
B) Unlubricated rings.
The standard ring of the short staple spinning mill the unlubricated type, can be considered under
the headings:
- Single sided rings,
- Double sided rings.

Single sided rings (Fig.2a) must be replaced by new ones after they are worn out; a double sided ring
(Fig.2b) worn on one sideand can be turned over and used on the second side. The later serves for mou
nting of the ring while the first side is acting as traveller guide.

For rings used in the short — staple spinning mill two dimensions are of prime importance; the internal
diameter and the flange width.
SUSANTA SEKHAR DE, Assistant Professor, Department of Textile Technology, GCETTS (WB, INDIA)

1. Internal diameter (mm): (36, 38, 40, 42, 45, 48, 51, 54)

2. Flange width (mm) Flange No. – 1 1½ 2

Flange width (mm) – 3.2 3.7 4.1

Materials for the ring

The ring should always be tough and hard on its exterior. The running surface in particular deserves the
closest attention. The surface layer must have high and even hardness (800-850 vikers). The traveler
hardness should be lower (650-700 vikers) so that wear occurs mainly on the travelers, which is easier
to replace and cheaper. Surface smoothness is also important.

The following materials are used:

- Flame, or induction, hardened steel, to some extent,

- Nitrided steel,

- Carbo-nitrided steel (this is the most common)

- Chrome steel (this is found more rarely).

The anti-wedge ring:

This was the first high performance ring. Compared with the previously standard ring form, it exhibits
on enlarged flange inner side and is markedly flattened on its upper surface. This change of form
permitted use of travelers with a lower center of gravity and precisely adapted bow (elliptical
travelers), which in turn allowed operation at higher speeds. Anti wedge rings and elliptical travelers
belong together and can be used only in combination.
SUSANTA SEKHAR DE, Assistant Professor, Department of Textile Technology, GCETTS (WB, INDIA)

The low crown ring (conventional ring):

In the low crown ring, the curvature of the surface has been somewhat flattened compared with rings
used up to that time. This gives more space for the passage of the yarn so that the curvature of the
traveler can also be reduced (oval, flat travelers) and the center of gravity is lowered. In comparison
with the anti wedge ring, the low crown ring has the advantages that the space provided for passage
of the yarn is larger and that all current traveler shapes can be applied with the exception of the
elliptical traveler. Today it is the most widely used ring form.

Both the above rings can be termed as T-flanged Ring as specified below:

T-flange ½ spinning ring is suitable for fine cotton yarns, used mainly in China.
T-flange 1 spinning ring is recommended for fine to medium yarn counts.
T-flange 2 spinning ring is ideal for coarse and special yarns.

T-flange ½ spinning ring T-flange 1 spinning ring T-flange 2 spinning ring

SUSANTA SEKHAR DE, Assistant Professor, Department of Textile Technology, GCETTS (WB, INDIA)

Under Oblique profiles of ring, we have Orbit ring and SU ring

Orbit Ring – Mainly two types as such as

a) An ingenious system of the redORBIT ring and the proper traveller was developed for spinning
top yarn qualities at highest speeds.
b) The ring ORBIT SFB is optimal for high speed applications, for combed cotton, PES
and PES/cotton blends.

Fig: RedORBIT ring Fig: ORBIT SFB Ring

SU ring:

It has two advantages, namely a large surface of contact for the traveler on the inner flange (with
correspondingly good heat transfer to the ring) and a degree of compensation of forces acting on the
traveler. SU rings with corresponding travelers permit higher traveler speeds, especially with synthetic
fibers and give a slight reduction in traveler wear.
SUSANTA SEKHAR DE, Assistant Professor, Department of Textile Technology, GCETTS (WB, INDIA)

A good ring should have the following features:

1. Best quality raw material,
2. Good, but not too high, surface smoothness,
3. Exact roundness,
4. Good, even surface hardness, higher than that of the traveler,
5. It should have been run in as well as possible
6. Long operating lifetime,
7. Correct relationship between ring and bobbin diameter (2:1 up to 2,2:1),
8. It should be exactly centered relative to the spindle.

THE TRAVELLER
SUSANTA SEKHAR DE, Assistant Professor, Department of Textile Technology, GCETTS (WB, INDIA)

Task and Function:

The traveler imparts twist to the yarn, and enables winding of the yarn on the cop. The speed
difference is due to lagging of the traveler relative to the spindle.

The traveler does not have a drive of its own but is dragged along behind the spindle.

High contact pressure (upto 35 cN/mm2) is generated between the ring and the traveler during
winding, mainly due to centrifugal forces. The pressure induces strong frictional forces which in turn
lead to significant generation of heat. This is the main problem. The low mass of the traveler does not
permit dissipation of the generated heat in the short time available. As result, the operating speed of
the traveler is limited.

Traveler Classification

Travelers are required to wind up yarns of very different types:

1. Coarse/fine;

2. Smooth/hairy;

3. Compact/voluminous;

4. Strong/weak;

5. Natural fiber/man made fibers.

Different parts of a traveller are depicted in the above picture

SUSANTA SEKHAR DE, Assistant Professor, Department of Textile Technology, GCETTS (WB, INDIA)

These widely varying yarn types can not all be spun using just one traveler type is needed. Differences
are found in: form, mass, raw material, finishing treatments of the material, wire profile, size of the
yarn clearance opening for the thread.

The Form Of Traveller

The traveler must be shaped to correspond exactly with the ring in the contact surface, with the
greatest possible surface area, is created between these two elements. The bow should be as flat as
possible, in order to keep the center of gravity low and improve smoothness of running. These two
features have a significant influence on the achievable traveler speed.

Fig: Traveller Shapes

The flat bow must still leave adequate space for passage of the yarn. If the yarn clearance opening is
too small, rubbing of the yarn on the ring leads to roughening of the yarn, a high level of fiber loss as
fly, deterioration of yarn quality and formation of melt spots in spinning of synthetic fiber yarns.

The Wire Profile Of The Traveller

Wire profile also influences both the behavior of traveler and certain yarn characteristics,
- Contact surface of the ring,
- Smooth running,
- Thermal transfer,
- Yarn clearance opening,
- Roughening effect,
- Hairiness.
SUSANTA SEKHAR DE, Assistant Professor, Department of Textile Technology, GCETTS (WB, INDIA)

In the figure wire profiles and average yarn clearance as a function of the traveler wire cross sections
are given.

The Material of the Traveller

The Traveller should be:

1. Generate as little heat as possible.
2. Quickly distribute the generated heat from the area where it develops over the whole volume of the
traveller.
3. Transfer heat rapidly to the ring and the air.
4. Be elastic, so that the traveller will not break as it is pushed on the rings.
5. Exhibits high wear resistance.
6. Be somewhat less hard than the ring, because the traveller must wear away in use in preference to
the ring.
SUSANTA SEKHAR DE, Assistant Professor, Department of Textile Technology, GCETTS (WB, INDIA)

In view of these requirements, travelers used in short staple spinning mill are almost exclusively made
of steel. However, pure steel does not optimally fulfill the first three requirements. Accordingly,
traveller manufacturers have made efforts over several decades to improve running properties by
surface treatment. Suitable processes for this purpose are:

*Electroplating, in which the traveller receives a coating of one or more metallic layers, (nickel and
silver)

*Chemical treatment of the surface to reduce friction and pitting.

The Traveller Mass

The traveller mass determines the magnitude of frictional forces between the traveller and the ring,
and these in turn determine the winding and the balloon tension. If the traveller is too small, the
balloon will be too big and the cop too soft; material take-up in the cop will be low. An unduly high
traveller mass leads to high yarn tension and many end breaks.

Accordingly, the mass of the traveller must be matched exactly to both yarn and the spindle speed. If a
choice is available between two traveller weights, then the heavier is normally selected, since it will
give greater cop weight, smoother running of the traveller and between transfer of heat out of the
traveller.

The Traveller Clearer

Yarn consists of fibers that are bound into structure more or less effectively, but that are in any event
relatively short. The yarn runs through the traveller, some fibers will be detached. For the most part
they float away into the atmosphere, but some remain caught on the traveller. These retained fibers
can accumulate until they form a tuft, and the resulting increase in traveller mass can lead to much
increased yarn tension which finally can induce an end break.
SUSANTA SEKHAR DE, Assistant Professor, Department of Textile Technology, GCETTS (WB, INDIA)

Traveller clearers are mounted close to the ring in order to prevent formation of such fiber
accumulations. They should be set as close as possible to the traveller without interfering with its
movements. Exact setting is vitally important.

RING AND TRAVELLER

Ring diameter, flange width and ring profile depends upon the fibre, twist per inch, lift of the machine,
maximum spindle speed, winding capacity etc.

Operating speed of the traveller has a maximum limit, because the heat generated between ring and
traveller should be dissipated by the low mass of the traveller within a short time available.

If the cotton combed yarn is for knitting, traveller speed will not be a limiting factor. Since yarn TPI is
less, the yarn strand is notstrong enough. Therefore the limiting factor will be yarn tension. Following
points to be considered

1) For 12s to 24s, 42mm ring with 180 mm lift can be used

2) For 24s to 36s, 40 mm ring with 180 lift can be used

3) For 36s to 60s, 38 mm ring with 170 mm lift can be used

4) For 70s to 120s, 36 mm ring with 160 mm lift can be used.

5) If winding is a problem, it is better to go for reduced production with bigger ring dia.

6) Anti-wedge ring profile is better , because of better heat dissipation

7) Elliptical traveller should be used, to avoid start-up breaks in hosiery counts

8)Special type of traveller clearer can be used to avoid accumulation of fibres on the traveller as the
traveller with waste does not perform well during start-up.

For polyester/cotton blends and cotton weaving counts yarn strength is not a problem. The limiting
factor will be a traveller speed. For a ring diameter of 40 mm, spindle speed up to 19500 should not be
a problem. Rings like Titan (from Braecker), NCN(bergosesia) etc, will be able to meet the requirements
For spindle speeds more than 20000 rpm, ORBIT rings or SU-RINGS should be used. As the area of the
contactis more with this ring, with higher speeds and pressure, the heat produced can be dissipated
without any problem. Normal ring and traveller profile will not be able to run at speeds higher than
20000 to produce a good quality yarn.

ORBIT rings will be of great help, to work 100% polyester at higher spindle speeds. Because, of tension,
the heat producedbetween ring and traveller is extremely high. But one should understand that, the
yarn strength of polyester is very high. Here the limiting factor is only the heat dissipation. Therefore
SUSANTA SEKHAR DE, Assistant Professor, Department of Textile Technology, GCETTS (WB, INDIA)

ORBIT RINGS with high area of contact will be able to run well at higherspindle speeds when processing
100% polyester.

While running 100% cotton, the fibre dust in cotton, acts like a lubricant. All the cottons do not form sa
me amount of lubricating film. If there is no fibre lubrication, traveller wears out very fast. Because
of this worn out or burn out travellers, micro-weldingoccurs on the ring surface, which results in worn
out ring surface, hence imperfections and hairiness increases in the yarn. Lubrication is good for West
African cottons. It may not be true with all the cottons from West Africa. In general there is a feeling,
cottons from Russia, or from very dry places, lubrication is very bad. If the fibre lubrication is very bad,
it is better to use lightertravellers and change the travellers as early as possible.

Traveller life depends upon the type of raw material, humidity conditions, ring frame speeds, the yarn
count, etc. If the climate is dry, fibre lubrication will be less while processing cotton. Traveller life is
very less when Viscose rayon is processed especially semi dull fibre, because of low lubrication.

Traveller life is better for optical bright fibres. Traveller life is better for Poly/cotton blends, because
of better lubrication between ring and traveler.

THE MACHINE DRIVE

About 20 % of production costs in spinning mill (tex 20) fall under the heading energy and of these
costs about two thirds are used in the ring spinning section.

In a ring spinning mill with 25000 spindles and an operating time of 7000 hours per year, a saving of
10% on an annual power bill of 1 million dollars will bring very interesting financial returns.

Power supplied to the ring spinning machine is absorbed by:

- the spindle (including the travelers) 65 – 70%

- the drafting arrangements 25%
- the ring rail 5 – 10%