Winding

Limitations of Spinning Technology

Progress in spinning automation and productivity
Despite of progress, it is still not possible to produce a
fault-free yarn
Depending on the raw material and state of the
machinery park, there are about 20 to 100 events over
a length of 1000 km yarn
Yarn exhibits a yarn faults every 1 to 5 km.
Yarn faults too thin, too thick, foreign fibre and dirty
places
Spinning process leads to formation of disturbing
faults

1. Machine parts - worn out or out of tolerance
2. Contamination trash, dust, seed coat fragments
3. Foreign material
These yarn faults cause disruptions in subsequent
processes productivity and quality
Hence spinner has to fulfill the demand of fault free
yarn by two measures
1. Prevent origin of yarn faults by adequate measure
- Choice of raw material, m/c maintenance and cleanliness in
mill
2. Remove yarn faults by the aid of yarn clearers
- Winding process



Reasons for Disturbing Yarn Faults
Winding Machine
Objects of Winding:
1. Extraction of disturbing yarn faults
2. Conversion of smaller package to bigger
package
3. Waxing of the yarn during winding process
4. Clearing foreign fibres
5. Clearing of Polypropylene
6. Detection of off-standard bobbins
7. Monitoring frequent yarn faults
8. Monitoring & documentation of quality data


Passage of Yarn through Winding Machine
Yarn Faults
Textile industry is dividing the yarn faults in
1. Frequently occurring faults
- Tested on Evenness Tester
- Expressed per 1000 m of yarn
2. Seldom occurring defects
- detected & eliminated during winding
- expressed per 1,00,000 m of yarn
Difference between Frequent faults & Seldom occurring
defects is mainly larger mass or diameter deviation and size

Classification of Yarn Faults
1. Neps
Faults that are less than 1cm and having a mass
increase of more than 100% are called Neps
They are basically produced due to immature
fibres / seed coat fragments in the raw material,
very short entanglements of fibres and yarns.
2. Short Thick Places
Faults with a length of 1 cm to 8 cm and having
a mass increase of more than 100%
These faults are basically produced due to short
fibres, improper draft control, bad piecing, flies
in spinning

Neps
Short Thick
3. Long Thick Places
Faults with a length of more than 8 cm and
having a mass increase of more than 45% are
called Long Thick places.
These faults are basically produced due to
thick places in sliver, roving etc.
4. Thin Places
Faults with a length of more than 8 cm and
having a mass decrease of more than 30% are
called Thin places
These faults are basically produced due to
missing sliver in drawing, stretches in sliver
and roving etc.

Long Thick
Long Thin
5. Count variations
Faults with a length of several meters and
having a mass increase / decrease of more
than 5% are called count variations
6. Foreign matters
Faults with a length of more than 1 mm and
visibility level of more than 5% are called
foreign matters
They are primarily produced due to mix up
of colour fibres, jute, hair, seed particles etc.

Count
Foreign Fibres
Yarn Fault Classification Matrix
Fault length in (cm)

F
a
u
l
t

s
i
z
e

(
%
)

Spectrum of Yarn Faults
Fault Length (cm)
-100%
0
+100%
+200%
+300%
+400%
+500%
+600%
0.1 2 1 4 8 16 32 64
. . . . . . . .
Unevenness
Imperfecti ons
Short
Thick
Pl aces
Long Thi ck Places
Long Thi n Pl aces
Basic setting of N S L T
For an easy setting of clearing limits Thick places are divided in to
NSL classes and
Thin place expressed as T
N channel - Less than 1 cm (to clear nep faults)
S channel 1.0 to 8.0 cm (to clear short thick place faults)
L - channel up to 200 cm (to clear long thick place faults)
T - channel up to 200 cm (to clear thin place faults)

Class Clearing Curve
Electronic Yarn Clearing
Yarn Faults Removing Principle

1. Yarn faults monitored by an
electronic device
2. As soon as yarn clearer detects a
yarn fault, the yarn will be
separated by the cutter
interrupting winding
3. Yarn fault removed by the suction
of the winding machine
4. Yarn splicing or knotting
5. Winding process continues up to
next fault


Yarn Fault Measuring Principle
Thickness of the yarn monitored and converted into a
proportional electrical voltage signal
Sensor monitors a yarn running up to 120 km/hr and , the
yarn is measured every 2 mm
Signal conversion is carried by
Capacitive measuring principle or
Optical measuring principle

1. Electrical measuring
condenser
2. Two electrodes
3. Electrical alternating
voltage
4. Yarn
5. Electrical signal

Capacitive Measuring Principle
Electrical signal corresponds to the yarn cross-section yarn mass
Changes of the yarn mass cause a proportional change of signal
1. Infrared light source
2. Diffuser
3. Photocell
4. Yarn
5. Electrical signal

Optical Measuring Principle
Electrical signal corresponds to the diameter of the usually round
yarn
Changes in yarn diameter cause a proportional change of signal
Cotton can be contaminated the cotton field to the spinning mill
Human and animal hair, feathers, strings, packing material,
stems, leaves and oil stains
Foreign fibers cause fabric defect, lower the efficiency of the
following processes




Foreign Fiber Clearing
Detection of Foreign and Polypropylene Fibers
Optical measuring system
Comparison between the reflection of the foreign
fiber and the normal yarn color
Classification Matrix - Uster

Classification Matrix - Loepfe