Indian Journal of Fibre & Textile Research

Vol. 20, December 1995, pp. 176-180

A study on measures to reduce infrequent yarn faults - Development of an

attachment
A Kanthimathinathan; M Kathirvel, K Gnanasekar, R Hariharan & K P Chellamani
The South India Textile Research Association, Coimbatore 641 014, India
Received 14 February 1995; revised- received and accepted 1 June 1995

A device has been designed and fabricated to be used at the back zone of ring frame to control the high
incidence ofiong thin faults, particularly at wider back zone settings. Trials conducted with this device show a
significant reduction (about 70%) in long thin and thick faults. Use of this device at the back zone of ring frame
does not affect the yarn evenness. However, Uster thin and thick places show a significant reduction. Mill level
trials also confirm the above findings.

Keywords: Back zone setting, Classirnat faults, Fault control bar, Roving twist multiplier

1 Introduction back zone setting in ring frame on Classimat long

Detailed surveys of the mixing and yarn quality in length faults has not been covered in this survey.
more than I()()mills exporting yarns and fabrics have Hence, the present study has been undertaken to
been done! by CfRAs during 1991-92.As per SITRA study the effect of wider back zone setting in ring
survey, the overall quality of export yarns frame on long length Classimat faults, and to suggest
corresponds to Uster 57% rating in coarse counts, measures to control long length Classimat faults at
70% rating in medium and fine counts and 84% rating wider back zone settings in ring frames.
in superfine counts. The various infrequent yarn
faults measured by the Uster Classimat System are 2 Preliminary Study on the Influence of Back Zone
also very high. In coarse and medium counts, the Setting in Ring Frame on Frequent and Infrequent
infrequent faults on an average meet Uster 70% Yarn Faults
standards and in fine counts, the fault level To reconfirm the influence of wider back zone
corresponds to as high as Uster 85% standards". settings in ring frame on Uster imperfections and long
Shah- has shown that long thin faults (H + I) are length Classimat faults, this study was conducted for
manyfolds higher than Uster 50% levels. Best values three counts, viz. 30s K, 40s K and 60s K. Evenness
of long thick faults (E + F + G) compare well with and imperfections at three different back zone
Uster 25% levels in most of the cases but the average settings in ring frame (Table I) clearly show that there
values of these faults are worse than even 50% Uster
levels.
Substantial reduction in Classimat faults is Table I-Evenness and imperfections at different back zone
reported to occur" by using a narrow bottom front settings
zone setting in speed frame. In ring frame, wider top Count Back zone Evenness Uster imperfections/Itxn) m
front zone setting results in excessive Classimat yarn setting U%
faults. But, in this study, no mention is made about the mm Thin & thick places Neps
effect of wider back zone setting in ring frame. The 30s K 51 15.6 1218 1590
survey" by SITRA on "Measures to produce yarns 55 15.8 1262 1612
meeting international quality standards for export" 60 15.2 1034 1490
40s K 51 16.1 1272 1026
has shown that use of wider back zone setting in ring
55 15.7 1138 1152
frame (60-65 mm) and lesser breakdraft (1.14-1.3) is 60 15.·2 924 909
prevalent in most of the mills covered in the survey. It 60sK 51 17.6 2119 2119
has also been observed that wider back zone setting 55 17.2 1876 2291
with lesser break draft improves yarn quality in terms 60 17.1 1895 2393
ofUster imperfections. However, the effect of wider
 KANTHIMATHINATHAN et af .. MEASURES TO REDUCE INFREQUENT YARN FAULTS 177

is a distinct trend for the evenness and imperfections similar concept may help to control fibre movement
to improve with wider back zone settings in ring at the back zone of ring frame and thereby to control
frame. Even though the difference in evenness and the tendency of Classimat faults to increase at the
imperfections at 51 mm and 60 mm of ring frame wider back zone setting. Accordingly, a fault control
setting is not statistically significant in individual bar has been designed and fabricated. However,
cases, the difference becomes highly significant towards optimizing the configuration of FCB, 4
taking all the counts together. This means that the different designs were made and their effect on
improvement in evenness and imperfections with Classimat faults evaluated. The 4 designs made are
wider ring frame back zone setting is real and shown in Fig.l.
consistent. Exhaustive studies made using 4 different bars
In the case of wider back zone setting with optimum showed that FCB of the type shown in Fig.1 c gives
break draft, twist in roving is broken up in a more better results. The results are given in Appendix I.
gradual manner which, in turn, helps to avoid FCB-I C was used for further large-scale trials. The
undrafted ends and short slubs in the yarn. If the slub positioning of FCB in the drafting zone of ring frame
is of a very high magnitude, it results in end breaks. On is schematically-shown in Fig.2. The device consists of
the other hand, if the slub is of a smaller magnitude, it a holder (I) which is clamped to the arm bar of the
is incorporated in the yarn and counted as Uster drafting system in the ring frame. The holder holds
imperfections. the long bar (2) which is projected towards the
However, the large scale adoption of wider back drafting system between top arms. The fault control
zone setting in ring frame critically depends on its bar (3) is connected to this long bar with the help of a
influence in infrequent yarn faults which are setting unit (4). The FCB could be positioned in
important from the point of view of the performance between the middle and back bottom rollers at a
of the yarn in weaving preparatory as well as during raised level to the line offlow of material. The FCB
the weaving and knitting processes and the extends over the length between the roller stands.
appearance and appeal characteristics of the fabrics.
3.] Effect of FCD on Classimat Faults
The long thin and thick faults in yarn at different
Using FCB, two counts, viz. 40s K and 40s C, were
back zone settings are given in Table 2. Both long
produced. 40s Combed yarn was produced with 18%
thick and thin faults increase with wider back zone
noil extraction. The major process parameters are
setting in ring frame. Between 51 mm and 60 mm of
back zone settings, the increase is rather statistically
significant. The probable reason for the increase in
Table 2-Long thick and thin faults-at different back zone
long thin and thick faults at wider back zone setting settings
could be the relatively high level of short fibre content
Count Back zone Long thick faults Long thin faults
in Indian cottons. The high short fibre content in setting (E+ F+G)/Iakh m (HI + II)/Iakhm
Indian cottons is supposed to result in some mm
uncontrolled fibre movement in the back zone. This 30s K 51 41 511
uncontrolled fibre movement creates mass variations 55 61 624
at the back zone which are extended in length by the 60 88 700
amount of draft in the main zone of the ring frame. 40s K 51 41 699
Hence, these mass variations are counted as 55 73 794
infrequent long thick and thin faults. 60 86 1180
60s K 51 61 1450
Therefore, unless some mechanism/method is
55 80 2090
devised to control the movement of short fibres in the 60 99 2379
back zone .and thereby to control the tendency of
Classimat faults to increase with wider back zone
setting, the benefit of using wider back zone setting
towards producing yarns with less imperfections can
not be fully realized.

3 Design and Development of a Fault Control Bar

(FeD)
In almost all the modern drawframes,an
attachment is provided at the front zone to control the
movement of fibres during drafting. Adoption of a Fig. I-Designs of fault control bar
178 INDIAN J. FIBRE TEXT. RES., DECEMBER 1995

given in the Appendix II. Classimat long thick and thin
faults for the two counts while using FCB in ring
frame are given in Table 3. In this experiment, ring
frame back zone setting was maintained at 60 mm.
For comparative purposes, Classimat faults without
using FCB in ring frame are also given in Table 3.
At 60 mm setting, while using FCB the long thin
faults decreased by about 80% and the long thick
faults by'about 60% as compared to that obtainable
without using FCB in 40s K yarn. It may be seen from
Table 2 that in medium and fine counts, Classimat
long thick and thin faults, on an average, increase by
about 70% when the back zone setting in ring frame is
increased from 51 mm to 60 mm. Hence, the broad
indication is that the level ofClassimat faults (long
thin and long thick) at 60 mm back zone setting with
FCB is more or less equivalent to that obtained at 51
mm back zone setting without FCB.
In the case of 40s carded yarn, while using FCB the
long thick faults decreased by 75% and the long thin
faults by 40%. The extent of decrease in faults here is
rather low as compared to that in 40s K. This is due to
the fact that the basic level oflong thin faults itselfis
lower in 40s C. This is again attributed to the relatively
lower level of short fibre content in 40s C mixing.
3.2 Effect of FCB on Evenness and Uster Imperfections
It has been established beyond doubt from the
above studies that the introduction of FCB helps to
decrease the Classimat long thin and thick faults
substantially. However, to find out the effect of FCB
on evenness and imperfections, a controlled study
was conducted for two counts and the results are
presented in Table 3. It is evident from this table that
the use of FCB decreases the Uster imperfections
(thin and thick), on an average, by about 50% in
addition to decreasing the Classimat long thick and
thin faults. The effect of FCB on evenness is not
significant.

3.3 Effect ofFCB on Long Leogtb Faults While Using Roving with
Fig. 2-A device for the reduction of long length faults in ring
frame [l-holder, 2-long bar, 3-fault control bar, and
4-setting unit)
Higher Twist Multiplier
Shah" has shown that the frequency of long thin
and thick faults decreases by about 30% with the use
of higher roving twist multiplier. No draft problems
were observed on the ring spinning machine in the
case of roving material having higher twist levels. It
was, therefore, considered of interest to see the
influence of FCB on yarn faults while using roving
with higher TM. Accordingly, a study was conducted
with a higher roving TM of 1.4 (Count, 40s K,

Table 3-Effect of FCB on classimat faults, evenness and Uster imperfections

Count Back zone Long thick faults Long thin faults Evenness Imperfections/IOOO m
setting (E + F + G)/Iakh IT. (HI + lJ)j1akh m (U%)
rom Thin & thick places Neps
Wihtout With Wihtout With Without With
FCB FCB FCB FCB FCB FCB Without With Without With
FCB FCB FCB FCB
40s K 60 12 5 446 93 13.6 13.4 1112 428 668 632
40s C 60 25 6 23 13 11.6 11.5 485 298 222 208

Table 4-Effect of FCB while using roving with higher twist multiplier for 40s K count

Roving Back zone Classimat faultsl1akh m Uster imperfections/lOOO m

TM setting
rom Long thick Long thin Thin & thick places Neps

WOB WB WOB WB WOB WB WOB WB

1.40 60 17 15 171 68 1143 453 614 630
WOB- Wihtout bar; and WB-With bar
 KANTHIMATHINATHAN et aI.. MEASURES TO REDUCE INFREQUENT yARN FAULTS 179

ase, probably due to the gradual breaking up of twist in

Table 5-Mill level trials using FCB
the roving. However, the Oassimat long thin and thick
Mill Count Ring frame Long thick fault: Long thin faults faults increase, probably due to the uncontrolled move-
No. back zone (E+ F+G)/ (Hl+ II)!
ment of short fibres during drafting.
setting lakh m lakhm
mm
5.2 The tendency of Classimat long thick and thin faults
WOB WB WOB WB
to increase at wider back zone setting of ring frame is
38s
Hosiery 51 24.2 12.5 36.0 12,3
controlled by the use of fault control bar (FeB) desig-
ned and fabricated at SITRA.
2 50s
Carded
45.0 27.0 800 390 S.3 Use of FeB at ring frame decreased the long thin
warp 60
3 60s
faults by 60-80% and the long thick faults by about
Combed 60 61.0 10.0 5503 3089 70%.
WOB-Without bar; and W~With bar 5.4 FCB also decreased the Uster imperfections. While
using FCB at 60 mm back zone setting, the various yarn
imperfections, on an average, decreased by about
Nominal TM, 1.25) and the results are given in Table 50%.
4. It is observed that by using FeB, long thin and thick 5.5 While using a roving of 1.40TM (normal TM, 1.25),
faults decreased by about 60% in 40s K yarn even FCB decreased the Classimat long thin and thick fa-
when roving with higher TM is used. It may, however, ults by about 60%.
be noted that the extent of decrease (60%) in
Classimat faults due to FCB (for roving of higher 5.6 Mill level trials also, by and large, confirm the findi-
TM) is slightly on the lower side as compared to that ngs ofSITRA pilot mill studies. In mill level trials, by
obtained while using roving of nominal TM (70%). incorporating FeB at the ring frame, long thin and
However;further studies are required to confirm this thick faults decreased by more than 50%.
trend.
While using roving of higher TM the imperfections Acknowledgement
also decrease (about 60%) due to the incorporation of The authors are thankful to MrT V Ratnam, Advis-
FeB in the back zone of ring frame. It is of interest to or, SITRA, for guidance throughout this work and to
note that the extent of decrease in imperfections at Mr K Sellamuthu, General Manager, Sree Shanmugh-
higher level of rovingTM is more or less same as that avel Mills, Dindigul, for permission to conduct the exp-
obtained in the case of normal roving TM while using eriments in their mills and also to use the testing instru-
FeB. Hence, irrespective of roving TM (within the ments at their R&D laboratories. They are also thank-
range covered), FCB helps to control long length ful to two other member mills for conducting trials us-
faults as well as Uster imperfections. ing FeB at their units and to their colleagues, particula-
rly Mr N Ramakrishnan, in Spinning and Textile Phys-
4 Mill Level Trials ics Division for help at various stages of this project.
To supplement the finding at SITRA pilot mill,
trials were conducted in 3 member mills of SITRA
with and without using SITRA's FCB in ring frame. References
The counts produced include 38s carded hosiery, 50s I Measures to improve the quality of export yams. A joint report of
carded and 60s combed. The results are given in Table ATIRA, BTRA, SITRA and NITRA (BTRA, Bombay).
5. It is observed that 60s combed yarn shows substarnial 1992.
reduction in terms of long thin and thick faults on 2 Seshadri S & Ramakrishnan N, A study on the quality of export
incorporation of SITRA's FCB at the back zone of yams, SITRA resea~ch report. 36(7) (1991).
3 Shah P H, Measures for reducing long thin faults in cotton yams
the ring frame. The extent of decrease is 50-65% in
through appropriate actions at speed and ring frames.
long thin faults and4O-50o/~ in long thick faults in all . Proceedings of the 34thjoint technological conference of A TI RA.
the three mills. BTRA. SITRA and NITRA (ATIRA, Ahmedabad), 1993.
53-58.
5 Conclusio~ 4 Chellamani P, Kanthirnanthinathan A & Karthikeyan S,
Measures to produce yarns meeting international quality
5.1 At wider ring frame back zone settings, the Uster standards for export. Mill control report No.7 (SITRA,
imperfections, particularly thick and thin places, decre- Coimbatore), April 1991.
180 INDIAN J. FIBRE TF.XT. RES., DECEMBER 199'1

AppeDdix I-Putiealars ofabe optimizatioil IriaI ofabe deslp of Appeadix II-Major .pMCe18parameten adopted
FCB Process parameter 40s K 40s C
[Count, 30sC; Drafting system- SKF PK 225;Backzone setting
at ring frame, 60 mm; and Break draft,l.3] Card sliver hank, Ne 0.15 0.15
Classimat Without With bar Comber noil extraction, % 18.0
fault type bar Finisher drawing sliver hank, Ne 0.15 0.15
A B C D Roving hank, Ne 1.5 1.5
Short thick 4769 4508 4495 4211 4369 Roving TM 1.25 1.40 1.25 1.40
Long thick 64 43 39 35 62 Ring frame back zonesetting"mm 6Oand7~
Long thin 423 340 318 .247 385 Spindle speed, rpm ---14000"----