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COMPACT SPINNING

The idea stems from the point about the necessity of controlling the dimensions of the spinning triangle to improve yarn strength and reduce yarn hairiness. It basically is a fundamental modification of the conventional ring-spinning system that aims at producing a better surface integrity of spun yarns and maximizing the fiber contribution to yarn strength.

The Spinning Triangle

In conventional ring spinning a width of the fiber strand undergoes dynamic


changes as fibers flow from the drafting zone to the twisting zone. As the fibers emerge from the nip of the front drafting rollers, the width (Wf) decreases to the width of the spinning triangle (WT), as the fibers enter the twisting point the width of the strand is reduced further to the thickness of the yarn being formed. The difference between the width of the fiber flow, WF, in the drafting system and the width of the spinning triangle, WT widens as the speed of the front roller increases or as the spinning tension increases. The former is due to the loss of fiber control, and the latter is due to the reduction in the spinning triangle width (WT). The continuous change in the width of fiber strand prevents some fibers from being fully incorporated in the yarn structure. These fibers will not fully share the loading of yarn under tensile stresses, leading to a loss in yarn strength.

These fibers are likely to form protruding hairs that can be stimulated further by the ring/traveler system. This means that some edge fibers will be under no tension control. Those fibers will not have the opportunity to fully migrate into the yarn, and in worst-case scenario, they are either lost or wrap around the already twisted yarn in a disorderly arrangement. The effect of those fugitive fibers on yarn quality will be reflected in high hairiness, low strength and low evenness.

Remedies
One conventional way is to increase the twist in the roving to an optimum level that will allow better compactness of the fibers during the drafting process (that is keeping the fibers sideways together). This method suggests that the roving twist can act as a fiber condenser mainly in the break-draft zone, and partially at the main draft zone. Another method of condensation is to use mechanical means. For example, a funnel shaped condenser, located between the aprons and the delivery cylinders. Such an element can in fact add a condensation effect to the fiber flow. The only disadvantage is that due to the rubbing action between the funnel and the fibers, the drafting action is disrupted leading to deterioration in yarn evenness, and increase in imperfections.

Remedies
The third possibility is by using aerodynamic condensation after the drafting zone, but before the yarn formation

As shown in Figure, the use of aerodynamic condensation after the drafting zone results in an approximately zero width difference (Dw) of the fiber flow reaching the spinning triangle. In addition, the spinning triangle shrinks to almost nothing

The introduction of compact or condensed spinning alters the view about the role of the spinning triangle in providing yarn strength through fiber migration. In the absence of such triangle, the opportunity for fibers to interact by inter-displacement is almost nonexistence. This opportunity is substituted by pneumatic compaction of fibers and by reducing the height of the triangle in such a way that even the shortest fibers are allowed to participate in the yarn structure In light of the above discussion, the idea of compact or condensed spinning is to minimize the change in the width of fiber strand through the introduction of a compacting media (air), and a substantial reduction (almost elimination) of the spinning triangle. Mainly the following systems were introduced earlier Rieter Com4 system Suessen EliTe system Zinser AIR-COM-TEX 700 system

Rieter Compact (Com4) Spinning

The drafting system consists of 3 over 3-roller drafting in which the bottom delivery roller is a hollow, perforated drum with a large diameter. The condensing zone follows directly after the drafting system, the exit roller being replaced by a perforated cage or drum, within which is a stationary suction unit which is connected to the machines central extraction unit.

The fibers delivered by the exit nip line of the drafting system are held on the surface of the perforated cage, moving at the cages peripheral speed. The stationary suction unit in side the cage has a slot which is adjusted to the raw material being processed. A vaccume is created within the suction unit and the fibers are pushed along the slot in the direction of the center of the yarn by the airflow created. This process is aided by an air control element on the perforated cage, which significantly increases the degree of efficiency of the air drawn in. The air current created by the vacuum generated in the perforated drum condenses the fibres after the main draft. The fibres are fully controlled all the way from the nipping line after the drafting zone to the spinning triangle. An additional nip roller prevents the twist from being propagated into the condensing zone. The compacting efficiency in the condensing zone is enhanced by a specially designed and patented air guide element.

Presentation on Comparison between


1. 2. 3. 4. 5. RoCos Rotorcraft compact spinning Olfil System Marzoli Zinser compact system Toyota compact system Elite Compact System

ADVANTAGES OF COMPACT YARN:


no singeing before printing intensive dye penetration greater brilliance of color higher abrasion resistance better imperfections (IPI) values fewer weak points lowest hairiness (highest reduction in hairs longer than 3 mm) same tenacity with reduced twist factor for higher production higher tenacity with same twist factor higher fibre utilization

Due to better utilization of fibre substance it is possible to reduce yarn twist of these Yarns, particularly of knitting yarns, by up to 20%,maintaining the yarn strength of conventional ring yarns. This increases yarn production. The ends-down rate in spinning these Yarns is reduced by 30 to 60%,which improves machine efficiency. Applying the same winding speed as with conventional ring yarns, there are less raised points in these Yarns and the increase in yarn imperfections is reduced because they have a better resistance to shifting. Higher winding speeds are therefore possible with compact yarns. In accordance with up to 20%twist reduction in spinning compact yarns ,the twisting turns can be reduced for certain types of yarn. As a result, production of twisting frame is increased and twisting costs are reduced. Owing to the lower hairiness and higher tenacity of compact Yarns, the ends-down rate in beaming is reduced by up to 30%.Higher beamer efficiency, higher production and fewer personnel for repair of ends-down in beaming are the consequence.

Compact Warp yarns help to save up to 50%of sizing agent, while the running behaviour of weaving machines is the same or even better. Cost can be saved in sizing and desizing processes. Owing to the better work capacity of compact Yarns ,ends down can decreased by up to 50% in the warp and by up to 30%in the weft. Efficiency is consequently increased by 2 to 3%, production is increased and weaving costs are reduced. In practice,the average endsdown rate is reduced by 33% per 100,000 weft insertions of compact Yarns on rapier weaving machines and by 45% on air-jet weaving machines. Instead of a weft insertion of 500 600 p/min with conventional ring yarn,700-800 p/min is possible with compact Yarns on air-jet weaving machines. Due to reduced Yarn hairiness, singeing can sometimes be dispensed with, or it can be carried out at a higher cloth advance speed. As a result, production costs are considerably reduced. fibres upto 7% can be saved because singing can be avoided Dyeing and Printing Improved structure of compact Yarns and their reduced twist favours the absorption of colour pigments and chemical finishing agents.Saving of dyestuff is possible.

Owing to the improved yarn strength, compact Yarns are well suited for non-iron treatment (e.g crepe finishes etc) of woven fabrics. In the course of such treatment,the strength of fabrics made from conventional ring yarns can decrease by up to 25%,with frequent problems in the manufacture of clothes. compcat Yarns make up for this loss in strength. Knitting :Compact Yarns with their increased yarn strength and reduced formation of fluff permit to achieve higher machine efficiency and therefore production on knitting machines at a reduced ends-down rate, less interruptions and less fabric faults. Production costs therefore decrease. The enormously low hairiness of compact Yarns often permits to dispense with usual waxing. Considerable cost saving is achieved because of this. In knitting fibre abrasion reduced by 40% due to low hairiness. Fewer defects/ yarn breaks and better quality. Less contamination on all machines by foreign fibres . Less wear of needles, guide elements and sinkers due to less dust in the compact Yarn . Low hairiness has positive impact on loop structure . Low pilling values get more and more important . In many cases single compact Yarns substitute conventional ply yarns. Waxing can be reduced or completely dispensed with .

Compact Yarns are much more suitable for warp knitting than conventional ring yarns, because of their higher work capacity and lower hairiness. They are predestined to bear the high load due to numerous deflecting points with high friction in the warp knitting machine. Due to better embedding of fibres (including short ones)in Yarn,approx.6%fewer combing noils are possible. compact

Cheaper carded qualities instead of combed qualities can be spun with the Compact Spinning system. in many cases single EliTe Yarns can substitute conventional ply yarns new qualities can be developed, opening up a new creative scope for products

Comparison between Compact and Ring yarn w.r.t Quality Spinning


Values of strength and elongation of compact yarns were found to be better than those of comparable ring-spun yarns. Zinser reported about 3% to 7% improvement in compact yarn strength over that of ring-spun yarn. Suessen reported that single EliTe yarns compare in strength with two-ply conventional yarns. Compact yarn exhibited less number of weak places than the conventional ring-spun yarn. Rieter reported a minimum value of only 2.2 cN/tex for ring-spun yarns compared to 12.5 cN/tex for compact yarn. Compact yarn exhibited considerable improvement in abrasion resistance- even with extremely low yarn twist; yarn abrasion resistance was about 25% better than the conventional ring-spun yarn. All systems revealed significant reduction in yarn hairiness-In some cases, the number of short hair (1, and 2 mm) were almost identical to those of the conventional ring-spun yarn. The advantage was clearly observed in the long hair (3mm or longer). Zinser reported a range from 5 to 14% improvement in yarn hairiness of compact yarn over that of ring-spun yarn. Suessen reported similar improvement.

All systems produced better yarn evenness and lower yarn imperfections than comparable ring-spun yarns. Compact yarns offer possibility of higher draft ratios (or using coarser input material). Draft ratios of up to 80 is claimed to be feasible. All systems revealed better yarn performance down the chain of processing. For example, Zinser reported that the condensed yarn yielded lower increase in hairiness upon winding than the conventional ring-spun yarn. Zinser also reported a reduction in condensed warp and filling stops during weaving even with a reduction in size add-on of 20%.

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