Short Staple Spinning: Bräcker AG Bräcker S.A.S

Short Staple Spinning
For Your Profit
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Our customers get the profit Swiss technology, know-how and service is transformed into hard cash for our customers. Our legendary Brcker manual shows you how you can increase your profit with Brcker technology, know-how and service. The manual gives information on: Brcker technology O Leading-edge technology for key components in spinning mills O Development, materialisation and manufacture of specific, high-grade, innovative products Brcker know-how O Our distinctive know-how in technology and components, developed and perfected over decades. O Competence in consulting and solution-finding, thanks to extensive market knowledge and a wide background of experience Brcker service O Our wide range of top-quality products for any application O The right solution for every yarn quality, with key components which are optimally matched to one another The result is a consistent increase in quality and productivity for you as a Brcker customer. We are looking forward to being a partner for your business. Brcker For Your Profit
Summary
Technical spinning information
Numbering systems for yarns and twists 6-7 Yarn breaks
page 5
8-10
Rings and Travellers C-shape ORBIT and SU travellers

Requirements for optimum results Spinning geometry Traveller speeds Traveller weights comparison chart flange travellers Security Designation of the ring traveller parts Wire sections Finishing treatments Traveller friction Yarn clearance Motions of the ring traveller Ring traveller/ring contact areas Hairiness Neps Processing of blended and synthetic yarns 4 5 6 7 8 9 0 - 4-5 6 7 8-0 - Core yarns Compact spinning Traveller delivery program for ORBIT and SU rings Traveller delivery program for flange rings Recommendation for Brcker travellers Traveller weights for T flange, ORBIT, SU Evaluation of traveller weight Setting of the traveller cleaner ORBIT ring/traveller system Ring travellers for ORBIT rings Traveller wear and tear Setting of the traveller cleaner SU-Ring/traveller system Ring travellers for SU rings Setting of the traveller cleaner
page 13
4-5 6 7 8-9 40-4 4 4 44-45 46 47 48 49 50 5 5
Rings and Travellers Spinning rings

Rings, range of application Ring profiles Ring shapes Brcker ring holder Assembly system Fixing methods Start-up proceeding for new rings 54 55 56 57 58 59 Ring life time Influence of the ring condition on the yarn quality Traveller wear, insufficient lubrication Ring load Ring load tables Designation of the ring parts
page 53
60 6 6 6 64-7 7
Rings and Travellers Inserting tools

Inserting tools for magazined travellers RAPID inserting tools for magazined travellers Brcker BOY 74 75 76 Magazining systems Brcker RAPID Traveller inserting and removing tools
page 73
77 78 79
BERKOL
BERKOL top roller covers Product qualities in the BERKOL top roller covers BERKOL Rubber qualities The BERKOL Alupress cover Grinding BERKOL circular grinding machine Type BGU BERKOL grinding system BGS 8 8 84 85-86 87-88 89 90 The surface treatment The new manual Berkolizer 06 machine Top roller size testing device Surface finish measuring device Lubrication LUBRIBOY BERKOL PU aprons
pages 81
9 9 9 94 95 96 97
Tools Yarn carriers Index

pages 99-101 pages 103-105 page 107
Technical spinning information
Numbering systems for yarns and twists

Conversion formulas
Desired Given Tex Decitex Den Metric no Engl. cotton no Engl. linen no Engl. woolen no Engl comb. no Abbreviation tex dtex den Nm NeC NeL New NeK
den 9 tex 0,9 tex 9000 Nm 55 NeC 488 NeL 7440 New 797 NeK
tex 0, dtex
dtex 0 tex
Nm 000 tex 0000 dtex 9000 den ,69 NeC
NeC 590 tex 5900 dtex 55 den
NeL 654 tex 6540 dtex 488 den
NeW 98 tex 980 dtex 7440 den
NeK 886 tex 8860 dtex 797 den
0, den , den 000 Nm 590 NeC 654 NeL 98 New 886 NeK 0000 Nm 5900 NeC 6540 NeL 980 New 8860 NeK
0,590 Nm ,654 Nm ,98 Nm 0,886 Nm ,80 NeC ,8 NeC ,5 NeC
0,605 NeL 0,57 NeL
,7 NeL 0,56 NeL 0,457 New
0,56 New 0,05 New 0,85 New
,9 NeK 0,667 NeK ,867 NeK ,88 NeK
Mass count
Weight Length
tex den
= =
g km g 9000 m
Length count
Length Weight
Nm NeB
= = = = =
m g 840 yds pound 00 yds pound 56 yds pound 560 yds pound (woolen) (worsted)
Twist with Ne T/ = ae Ne with Nm T/m = am Nm with tex T/m = atex tex
Twist multiplier with Ne ae = with Nm am = with tex atex = T Ne T/m Nm T/m tex
NeL NeW NeK
Weft twist Knit twist
p Warp x 0,9 p Warp x 0,8
Numbering systems for yarns and twists

Yarn count comparison chart (rounded figures)
tex 00,0 84,0 7,0 64,0 60,0 56,0 50,0 46,0 4,0 6,0 4,0 ,0 0,0 5,0 ,0 ,0 0,0 7,0 4,0 ,5 ,0 0,0 8, 7,4 6,6 5,8 5,5 5,0 4,0 , Nm 0,0 ,0 4,0 6,0 7,0 8,0 0,0 ,0 4,0 8,0 0,0 ,0 4,0 40,0 44,0 48,0 50,0 60,0 70,0 80,0 85,0 00,0 0,0 5,0 50,0 70,0 80,0 00,0 50,0 00,0 NeC 6,0 7,0 8, 9,5 0,0 0,6 ,0 ,0 4,0 6,5 8,0 9,0 0,0 4,0 6,0 8,0 0,0 6,0 40,0 48,0 50,0 60,0 70,0 80,0 90,0 00,0 05,0 0,0 50,0 80,0 NeK 8,9 0,6 ,4 4, 5,0 6,0 7,7 9,5 , 4,8 6,6 8,4 0, 5,4 9,0 4,5 44, 5, 6,0 7,0 75, 88,6 04,5 9,6 NeW 9,4 , 7, ,0 ,0 5,0 9,0 4,0 47,0 54,0 58,0 6,0 66,0 78,0 85,0 9,0 97,0 6,0 6,0 55,0 NeL 6,5 9,8 , 6,5 8,0 9,8 ,0 6,4 40,0 46,0 50,0 5,0 56,0 66,0 7,0 79,0 8,0 99,0 6,0 ,0 40,5 65,4 95, , den 900 750 64 56 59 500 450 409 75 00 8 65 5 05 88 80 50 9 08 90 75 67 60 5 50 45 6 0
Yarn breaks
General By reducing yarn breaks, the spinning costs become lower and the productivity increases. By selecting the right ring and traveller, these performances can be substantially influenced. How does a yarn break? When the current spinning tension in the spinning process is higher than the current yarn strength. Practically, this means that a thin place in the yarn and a peak in tension occur simultaneously. Influence of the speed on yarn breaks At higher speeds more yarn is being produced. As the yarn breaks are mostly counted per time unit, the latter has to be considered. At higher speeds (with identical spinning geometry) the spinning tension is bound to be higher. The yarn strength however does not change, therefore the probability of yarn breaks does increase. Therefore on state-of-the-art ring spinning machines the spindle rotation is adjusted accordingly (reduction on the base and top of the cop).
5 0 Spinning tension: 05% of the yarn strength Thin place Tension peaks Yarn break Yarn strength % 00 95 85 Yarn strength in the spinning process 85-95%
Distribution of yarn breaks while building up of the cop
Cop build-up
Yarn breaks
Causes of yarn breaks

Yarn breaks can have different causes. A perfect ring condition and the selection of the right travellers are of utmost importance. If yarn breaks do suddenly increase substantially, other factors, whole spinning process stages as well as the climatic conditions should be considered in addition. In general, we distinguish between kinds of yarn breaks: Breaks during spinning process
Cause of yarn breaks Caused by ring and traveller Unsuitable traveller type Spinning tension too high resp. too low Uneven spinning tension, yarn tension peaks Poor condition of the ring Running time of the travellers Caused by drafting components Top roller covers worn out Top roller cover too hard Wrapping tendency of the top roller cover Top roller cover surface to glazed, berkolizing process too long Film forming, smoothing of surface Run-out fault of top or bottom roller Rough-running, damaged top roller bearing Poor gliding aprons Fluff accumulation in the cradle Caused by other factors Insufficient yarn strength related to the selected speed Yarn evenness Raw material Climatic conditions not optimal, fly Remedy (corrections / solutions) Try another traveller shape, wire profile Adjust traveller weight, strive for a well-balanced balloon Re-centre rings, anti-ballooning rings and thread guides Replace rings Test wear and tear, shorten the replacing cycles Regrinding of the top roller covers, ev. replacement Select softer top roller type Surface treatment through berkolizing Regrinding the top roller covers, reduce berkolizing time Regrinding of the top roller covers, ev. replacement Regrinding of the top roller covers, aligning of the bottom rollers Replace complete axes Wash or replace aprons Choose other apron Adjust the spindle speed to the yarn strength (knit yarns show a reduced strength). Check spinning preparation, drafting system Analyse modification of the fibre quality resp. softening agents of chemical fibres Optimise climate, adjust blower and exhaust installation
Breakage during doffing

Yarn unthreading from travellers Setting of the machines Balloon stability too slowly built-up Traveller jammed High curling tendency of the yarn Change traveller type (shape, profile), pay attention to toe gap Adjust the lowering speed of the ring rail, check start-up program (compare with other machines). Run up faster, increase traveller weight Check condition of the ring, change type of traveller Delay start-up of drafting system
Yarn breaks
Basic data
Ne 0 0 40 Nm 40 50 70
Example of annual loss in production due to yarn breaks
Production/spindle/hour in grams 5.8 .7 5.7 10 min. 8'000
Average duration of breakage: Hours of operation in 1 year:
Depending on the breakage rate, the annual loss in production can be calculated, based on the following example: Annual loss in production (in tons)
Ne 20 No of yarn breaks 20'000 Spindles 30'000 Spindles 50'000 Spindles 20 9. 8.7 47.8 30 8.7 4. 7.8 40 8. 57.5 95.8 20 . 8. 0. Ne 30 30 8. 7. 45.5 40 4. 6. 60.5 20 8.4 .6 .0 Ne 40 30 .6 8.9 .5 40 6.8 5. 4.0
Ne 20 Annual loss in production by '000 spindles in tons
Ne 30 Ne 40
Breakage rate per '000 spindles/hour
0

C-shape, ORBIT and SU travellers
Rings and Travellers

Requirements for optimum results with Brcker rings and travellers

The spinning geometry of the spinning machines should be adapted to the yarns produced. By modifying these parameters, the following values should be considered. Important is the centring of the spinning rings, anti-ballooning rings and thread guides towards the spindle. This guarantees (together with perfect ring raceway and correct selected travellers) best yarn quality. Thread guide O Distance top of the tube/thread guide = .5 to x tube (ring rail position at starting position) Anti-ballooning ring O Anti-ballooning ring = ring + mm O Distance ring rail/Anti-ballooning ring (ring rail position in starting position) = / of the distance ring rail/thread guide Spinning ring O Spinning ring : max /5 of the tube length (exception Core Yarns) see chart below O Horizontal, firm fixation of the rings in the ring rail. O Correct setting of the traveller cleaner (see pages 44, 45, 49, 5) Ratio ring-/tube-/tube length
Medium tube- (mm) 6 7 8 9 0 7 8 9 0 4 8 9 0 4 5 9 0 4 5 6 0 4 5 6 7 Ring- (mm) D 36 38 40 42 45 48 51 54 70 80 90 00 0 0 0 40 Tube length (mm) L 80 90 00 0 0 0 40 50 90 00 0 0 0 40 50 60 00 0 0 0 40 50 60 70
L
Ideal range
Unfavourable range
4
Spinning geometry
see also page 4
Relation yarn count/ring diameter/flange type/traveller speed

The spinning geometry is determined (exception sewing thread) by the yarn count: A Flange A Long tubes O Coarse counts A Large ring diameter A Small ring diameter A Flange A Short tubes O Fine counts The maximum traveller speed is determined (with an optimum spinning geometry) by the yarn count and the twist rate.
Weaving yarn
v traveller m/s
Knitting yarn
Yarn count Ne
Recommended ring diameter 51/48 mm M 54 mm Recommended flange type Flange 1 Flange 2 ORBIT SFB 2.8 Ratio ring diameter/tube length The ideal ratio ring diameter to tube winding length is :5 (see page 4) 45/42 mm 40/38 mm 36 mm
5
Traveller speeds/performance calculations

in m/s (rounded figures), ring diameter 3670 mm
Formula: ring diameter x x n = m/s 000 x 60
Ring-
Feet/min: ~ m/s x 00
mm Inch
70 67 6 /4 5/8 / 4 6 8 40 4 5 6 8 40 4 4 45 9 4 6 8 9 4 4
60
57 54 5 48 45 4 40 8 6
/8 8 9 4 6 7 9 40 4 44 45 /4
/8

7/8 /4
5/8
9/6 /
7/64
Performance calculations Delivery: n = m/min L = T/m Production: L x tex x 60 x = g/h Ppr = 000 or n x tex x 60 x = g/h Ppr = T/m x 000
6
9 000 9 500 0 000 0 500 000 500 000 500 000 500 4 000 4 500 5 000 5 500 6 000 6 500 7 000 7 500 8 000 8 500 9 000 9 500 0 000 0 500 000 500 000 500 000 500 4 000 4 500 5 000
9 000 9 500 0 000 0 500 000 500 000 500 000 500 4 000 4 500 5 000 5 500 6 000 6 500 7 000 7 500 8 000 8 500 9 000 9 500 0 000 0 500 000 500 000 500 000 500 4 000 4 500 5 000
Spindle speed n/min
5 7 8 0 4 5 7 8 40 4 5 6 8 9 4 5 6 8 9 4 4 4 45 4 5 6 8 9 0 4 6 7 8 40 4 4 4 5 6 7 9 0 4 5 6 7 9 40 4 4 44 4 6 7 8 9 0 4 5 6 7 9 40 4 4 4 44 0 4 5 6 7 8 9 0 4 5 6 7 8 9 40 4 4 44 45 9 0 4 5 6 7 8 9 0 4 5 6 7 8 9 4 4 4 4 5 6 7 8 9 0 4 5 6 7 8 9 40 40 4 4 4 45 46 47 48 49 50 4 5 5 6 7 8 9 0 4 5 6 7 8 9 40 4 4 4 4 44 45 46 47
Spindle speed n/min
L n
= Delivery in m/min. = Spindle speed in min-
Ppr = Production in practice T/m = Twists per m g/h = Gram/hour (spindle) = Efficiency
Traveller weights comparison chart flange travellers

Traveller weights in mg resp. per 1000 travellers in g
The International Standard ISO 96- for travellers specifies the traveller weight in an even percentile grading according to the ISO R0 series. The weight increases from number to number by .5%: 00 + .5% + .5% + .5%... Exceptions (in brakets): Series R40 = 00 + 6.5% + 6.5% + 6.5%... Brcker travellers are produced in accordance with ISO 96-. Only numbers in bold print are ISO numbers
Conv. Traveller No 8/0 6/0 4/0 /0 0/0 9/0 8/0 7/0 6/0 5/0 4/0 /0 /0 /0 0/0 9/0 8/0 7/0 6/0 5/0 4/0 /0 /0 /0 35.5 ISO No, respectively traveller weight in mg Brcker Kanai * R+F Carter ISO Chinese FO/690 6.3 6.7 5.0 4.5 7.1 8.0 9.0 10.0 11.2 12.5 (.) 14.0 (5.0) 16.0 (7.0) 18.0 20.0 22.4 (.6) 25.0 28.0 31.5 40.0 45.0 50.0 56.0 63.0 71.0 80.0 8. 9.5 0.9 . .0 .7 4.5 5.4 6.6 8. 20.0 .6 .4 4.8 6.8 8.5 0. . 8. 4. 48. 54.6 6. 74.0 8.0 6.0 7.1 8.0 9.0 10.0 11.2 .8 (.) 14.0 (5.0) 16.0 18.0 (9.0) 20.0 22.4 (.6) 6.5 0.0 31.5 35.5 (4/0) 40.0 45.0 50.0 60.0 71.0 80.0 4.8 8. . 4.6 6. 7.8 9.4 . .7 4. 5.9 7.5 9. 0.8 .4 4.0 5.6 (7/0) 8.9 4. 45.4 48.6 5.8 58. 64.8 7. 77.8 Conv. Traveller No 4 5 6 7 8 9 0 4 5 6 7 8 9 0 4 6 8 0 4 6 8 40 ISO No, respectively traveller weight in mg Brcker Kanai * R+F Carter ISO Chinese FO/690 90.0 89.0 85.0 84. (95.0) 100 112 125 140 160 180 200 224 250 (65) 280 (00) 315 (5) 355 (75) 400 (45) 450 (475) 500 (50) 560 (600) 630 (95.0) 09 6 54 75 200 0 45 (65) 86 (00) 315 5 40 355 8 40 45 460 490 545 595 650 700 750 (95.0) 06 112 125 140 160 180 200 224 (6) 250 (65) 280 (00) 315 5 355 85 45 450 (475) 90.7 04 7 0 50 68 95 4 4 5 7 85 98 4 7 6 89 45 440 467
35.5 (5/0) 5. (5/0)
Example: Travellers with the same weight have different conventional traveller number.
7
* Only coated travellers, main types
Security
Travellers
Utilize eye protection
Adequate eye protection is required when working with travellers O Inserting O Removing O Observing O Yarn piecing
Tools
ROLSPRINT, ROLTEx, CUTEx, SECUTEx, CLIx Do not point with spindles and spiky tools towards persons.
8
Designation of the ring traveller parts

C-shaped travellers
Inner traveller width Height of bow Yarn passage 4 Wire section 5 Traveller ring contact surface 6 Angle of toe 7 Toe 8 Opening 9 Upper part of traveller bow 6 9 5
8 7 4
9
Wire sections
The wire section does influence the yarn quality, the running behaviour, the performance and the life time of the travellers. The right choice of the wire section is an important factor for optimum results. Only for cotton: improves the traveller lubrication.
flat
Synthetics and blends: prevents fibre damage. Fine cotton yarns: reduces production (push-back) neps.
dr
half round For cotton and blends: Through an enlarged contact surface on the ring raceway, highest performances are possible. Most used wire section.
udr ultra (wide) half round For Core yarns with PES core, acrylics and delicate fibres. f-profile at the toe increases the ring contact. r-profile for fibre protection in the yarn passage. fr flat/round Special profile for SU travellers. Application for Viscose and Polyester.
drh half round high

0
SFB travellers: udr, dr profile.
Finishing treatments
Travellers with an additional finish show the following advantages: O Higher traveller speeds O Longer traveller life O Improved running behaviour and as a result a more consistent yarn quality O Rust/oxidation protection (specially STARLET) O High performance travellers are only available with a finishing treatment SAPHIR Diffusion treatment Brcker SAPHIR has been especially developed for high performances. The enrichment components are present throughout the entire traveller section and do generate their effect even when the surface is affected. SAPHIR can be used for the ring running-in, normal operation and covers the entire fibre and yarn count range. STARleT electrolytic surface treatment (special nickel plating) A nickel coating is applied with a special process. Low friction values in the yarn passage prevent fibre damages. Optimum resistance to corrosion. PYRIT PYRIT treated travellers have a enriched steel structure through additional components. The wear resistance is considerably increased. This improves the running behaviour and guarantees a more consistent yarn quality. At high speeds the traveller service life can be increased by more than 00% compared to travellers with conventional finish.

Traveller friction
The traveller has, among other duties, the function to regulate the spinning tension. This spinning tension must be high enough to keep the thread balloon stable and, on the other hand, not too high in order to avoid yarn breaks due to tension. The ring/traveller system in the short staple spinning operates dry. At high speeds normal friction systems only work with additional lubricants. The ring/traveller system does only function thanks to this so-called fibre lubrication. As a result, the fibres protruding from the yarn body between ring and traveller are crushed and form a steady regenerating lubrication film.
Lubricating film
Depending on the fibre (dry or strong wax-containing cotton or softening agents on synthetics) the resulting coefficient of friction varies. The coefficient of friction of the fibre lubrication can vary in extreme cases from 0.08 to 0.. This is the reason, why in some cases for identical spinning conditions different traveller weights must be applied.
Fibre lubrication

Traveller friction
The spinning tension is the result of the following values:
Parameter Traveller weight Ring diameter Traveller speed Coefficient of friction Depending on Yarn count, spinning geometry Spinning geometry, machine Spindle speed, ring diameter Fibre, yarn hairiness, use of existing resources.
Example: A A traveller with 40 mg weight C and a coefficient of friction of 0.08 B develops about the same friction as a traveller with 28 mg weight C and a coefficient of friction of 0.12
Traveller friction mN 50 00 Traveller weight in mg 40 5.5 .5 8
00 50
00
0.08
0.09 0. 0. Coefficient of friction e
Formula R=eN
R e N Fz = = = = Traveller friction in mN Coefficient of friction m x v Normal force M Fz L r Centrifugal force Mass of the traveller in mg Traveller speed in m/s Radius of the ring (inside) in mm
mL = v r = =

A
0.
50
Yarn clearance
The yarn clearance must be adapted to the yarn count, yarn twist (volume) as well as to the fibres processed. The yarn clearance does also influence the fibre lubrication (see page ): O Reduced yarn clearance O Large yarn clearance A good lubrication A reduced lubrication O low-bowed traveller O reduced yarn clearance O low centre of gravity for fine cotton yarns for compact yarns O Optimum fibre lubrication
O low to medium bowed traveller O small to medium yarn clearance for fine to medium fine cotton yarns O Normal fibre lubrication
O high-bowed traveller O large yarn clearance for medium to coarse cotton yarns, also suitable for blends and synthetics (see page ) O Reduced fibre lubrication
4
Yarn clearance and its influence on the traveller lubrication

The required yarn clearance in the traveller must be selected according to the yarn count and to the fibres processed. It is determined by the traveller shape and the inclination of the traveller (see also page 6). Effects of the yarn clearance on the yarn quality and the running behaviour of the traveller:
Yarn clearance Yarn count Fibre Influence on lubrication film Influence on yarn quality Small, low Fine Cotton Good traveller lubrication Danger of push-back neps and melting points (on synthetics). Large, high Coarse Synthetics, blends Reduced traveller lubrication Excellent yarn quality guaranteed
The inclination of the traveller is primary influenced by the spinning geometry and the spinning tension. The stronger the inclination of the traveller, the more the yarn clearance is reduced and the better the traveller lubrication. The influences of traveller shape and inclination are shown in the following pictures: low-bowed traveller
Position
vertical (theoretical position)
medium inclination
strong inclination
High-bowed traveller
5
Motions of the ring traveller

The traveller has, among other functions, the important task to level out the different balloon forces. The following parameters are decisive: O Ring rail stroke over build-up of cop (influence of tube length) O Ring rail stroke during one traverse (small-/ large cop diameter) determines the traveller pulling angle a O Variations of speeds over cops build-up O Disturbing elements and influences (fly, turbulence, etc.) O Coefficient of friction ring/traveller (fibre lubrication)
Top of taper
Spinning on empty tube: a large Bottom of taper
Tight balloon
Spinning on full cop: a small
Soft balloon
The traveller changes its position during its work on the spinning ring in addition to the circular movement in different directions: O Tilting motion K O Pitching motion N O Radial motion R These motions are caused by the balloon forces variations. They are shown in the pictures.
K N
Conclusion The traveller is the levelling element in the spinning process. The right adjustment resp. choice of traveller under consideration of all mentioned parameters are decisive for the performance and the yarn quality.
6
Ring traveller/ring contact areas

The ring traveller is subjected to tension forces from the thread balloon (see page 6). This makes defining the contact area between ring and traveller very complex. By combining the traveller's arc radius with its wire profile, the desired large traveller contact area is achieved already during the starting phase of a newly replaced traveller. Traveller position and balloon shape on the top of the taper during spinning/winding
Traveller position and balloon shape on the base of the taper during spinning/winding
Examples of traveller positions Calculated in practice (after running for hours) Yarn passage
Contact area
7
Hairiness
Appearance
Yarn hairiness We speak of yarn hairiness when the body of the yarn has an exceeding number of long hair protruding out of it. Cop hairiness
We speak of cop hairiness when the outer side of the cop has an exceeding number of long hair protruding out of it.
Measuring methods The following measuring devices are on the market: O Uster Tester /4
O Zweigle G566567 Hairiness Tester
Hairiness measuring methods see page 0.

Further information on our Info sheet 805 Hairiness of yarn and cop in ring spinning.
Hairiness as a disturbance factor Hairiness is considered as a disturbance in the following operations: O Sizing machine (lateral hooking) O Warping, beam warping (dust) O Rewinding O Weaving (weft bars)
Kind of hairiness Yarn Cop Cause
Symbols
Yarn hairiness
Cop hairiness
Remedy O Replace rings (heavier ring travellers only rarely or temporarily bring improvement, yarn breaks increase)
Ring condition O Rough gliding surfaces reduce the braking effect of the ring traveller or disturb smooth running.
Traveller weight too light: O Poor twist contraction of the fibres on the spinning triangle O Heavy friction of the balloon on the anti-ballooning ring resp. impact on the balloon separator O Poor twist propagation to the spinning triangle.
O Increase traveller weight or choose another traveller type
Too heavy traveller or too much wear on the traveller: O Friction of the yarn leading to roughening and hairiness O Traveller wear in yarn passage area, causing roughening
O Reduce traveller weight or choose another traveller type O Reduce traveller running time
8
Hairiness
Appearance
Kind of hairiness Yarn Cop Cause Uneven yarn tension O Poor ring centring O Poorly centred thread guides O Thread guides with rough surfaces O Open anti-ballooning ring O Crooked tubes Remedy O Re-centre rings, spindles resp. thread guides O Replace damaged parts O Closed anti-balloon rings O New tubes
Yarn passage O Yarn is roughened in narrow yarn clearance O Scratched up yarn passages catch the yarn and roughen it
O Use a traveller with a larger yarn clearance O Reduce traveller running time
udr dr f
Wire profile O Adjust traveller weight O The wire profile can influence the yarn tension O If necessary, adjust the traveller weight Cop diameter O Set the cop diameter to the O Fibres protruding from the cop largest possible size are caught by the traveller and O Use beard breakers cut. This function does not work if distance between traveller and cop is too large. Electrostatic O The fibres get electrostatically loaded (direction of charge +/without significance) Crippled cops O Effect of the beard breaker fails O Increase air humidity O Assure conductive discharge with isolated ring rails
O No remedy possible, however, improve general running behaviour
9
Hairiness
Measuring methods
Uster Tester 3 und 4 O Method: A beam of light is directed on the yarn. The protruding fibres reflect the light and its intensity shows the hairiness value H (dimensionless value). O Hairiness H: Total length of the protruding fibres within the measuring panel of cm (e.g. H 4 corresponds to 4 cm fibres on cm yarn). The value H is dimensionless. Measuring in combination with mass, IPI, neps. O Evaluation of: medium hairiness/CV-hairiness, spectrogram. O Uster Standards for hairiness available O Further information: www.uster.com Zweigle hairiness measuring device G 566G 567 O Method: The fibres protruding from the body of the yarn are counted and classified to the following length rates: , , , 4, 6, 8, 0, , 5, (8, , 5) mm O Measuring length m O The S value is the sum of all hairs M mm. O The index is a reference and can be taken as a standard value only when other rates have been selected. O Further information: www.zweigle.com
Please note: O Hairiness is being measured on cops and bobbins and can not be directly compared with each other (bobbins show a higher hairiness).
0
Neps
When neps are mentioned in connection with rings and travellers, it means production neps. They do occur merely (and they are measurable) on yarns Ne 40 and finer. Formation of neps Production neps do mainly occur in the upper half of the cop and on the top of the cone. It is the matter of pushed-back, retained fibres and they do arise on tight gliding points and edges as well as at too high spinning tensions.
Production neps Cause Yarn clearance too tight Yarn passage intersects with the wear and tear spot Unsuited wire profile Spinning tension too high Notched thread guide Remedy Select a traveller with a higher bow Reduce life time, select a lighter traveller Change from f to udr, resp. from udr to dr Select a lighter traveller Replace
Yarn clearance
Yarn passage
Wear and tear area
When yarn passage and wear and tear area separated: No risk for neps.

When yarn passage intersects with wear and tear area: Formation of neps possible.
Processing of blended and synthetic yarns

Important points
Thread guide Notched or slightly torn thread guides damage the fibres and roughen the yarn. Remedy Replace guides
Remedy Apply heavier travellers to reduce friction on the anti-ballooning ring. In extreme cases, remove anti-ballooning ring (avoid balloon hitting on separators!).
Anti-ballooning ring A large bulging balloon increases the friction on the antiballooning ring, leading to mechanical and thermal fibre damages.

Yarn passage Operating at high traveller speeds, the contact area of the traveller with the ring can become very hot. If the yarn runs too close in this area, damages might occur.
Remedy Use travellers with defined position of the yarn passage (C UM, C LM). For Core yarns with PES filament core use fr profile. Reduce speed if necessary.
Ring crown If the yarn touches the ring crown, thermal damages can occur. In addition, the yarn will be roughened.
Remedy Use travellers with defined position of the yarn passage (C UM, C LM). Use rings with a lower ring crown (Brcker rings).

Core yarns
Yarns with a filament core, which are covered by staple fibres (wrapping fibres). When processing core yarns it must be avoided that the wrapping fibres get pushed back at the guiding points, in particular in the yarn passage of the traveller. The traveller speeds are limited with such yarns. We distinguish between: O Hard core O Soft core
Core
A Filament core made of PES (for sewing thread, etc.) A Elastic filament core (Spandex, Lycra, xLA, etc.)
Hard (PES Filament) Soft (Spandex)
Characteristics
Very delicate yarn for spinning. Due to the smooth surface of the filament, the wrapping fibres do adhere insufficiently and may be pushed back. The lower the ratio filament to the covering fibres, the more critical is the processing.
When running at normal (reduced) speeds, regular rings and travellers can be used. Avoid over-stretching of the elastic core thread.
Special attention Travellers Shape Wire section Weight
Push back of fibres
With fine counts, perfect core guiding is required
High-bowed travellers fr / r (coarse counts dr)
Use regular traveller shapes (as for cotton). dr or udr
Higher weights compared to regular yarns Lighter travellers compared to regular See table page yarns See table page 0 to 5 m/s 68 to 6 h 5 to 0 m/s 68 to 6 h
Traveller speeds Traveller life time Rings Ring finish Remarks Traveller lubrication Anti-ballooning rings
Thermo800
All types, including TITAN
Poor lubrication Avoid, if possible
Normal, sufficient for above mentioned traveller speeds.
4
Core yarns
Traveller weights
Hard (PeS-Filament) Traveller recommendation, guiding values The effective traveller types and numbers should be evaluated through trials
Yarn Count Ne Traveller No ISO Traveller No low high low high Flange 2 Recommended traveller types 6 8 10 12 14 16 20 24 30 90 4 7 40 6 80 50 50 6 /0 60 40 50 4/0 /0 80 50 50 00 80 60 5 00 6 0 4 8 4 8 4 0 8 0 6 9 H 2 fr C 1 SH fr Flange 1 C 1 SM fr EM 1 fr
55 5 5 50 4 00 60 40
C 2 HW dr, H 2 dr
Soft (Spandex) Traveller recommendation, guiding values The effective traveller types and numbers should be evaluated through trials
Yarn Count Ne Traveller No ISO Traveller No low high low high 8 10 12 14 90 4 7 16 7 90 4 20 56 7 /0 24 50 6 /0 30 56 /0 /0 40 45 /0 50 8 7/0 60 5 8/0 70 8 5 8/0
40 00 9 7 9 6 8
45 5,5 ,4 0
80 40 5
5/0 0/0 /0 /0
Traveller types: same as for cotton yarns (see page 40)
5
Compact spinning
Compact spinning systems generate yarns with the most reduced hairiness. The fibre lubrication for the ring/traveller system is reduced and results in a poor lubrication. By using best suited rings and travellers the compact yarns can be processed under optimum conditions. Ring shape O Flange rings for normal to high speeds O ORBIT rings for highest performances. Restricted yarn count range (see application recommendation page 46) Ring finish O TITAN for the entire range of application Travellers O Low yarn clearance, ultra half round (udr) and half round (dr) profile (ORBIT) Application recommendation Guiding values, the effective traveller types and numbers should be evaluated through trials
Yarn No Ne Rieter Com4 10 12 14 16 20 24 Flange with C EL udr Compact yarn
Conventional ring yarn
30 45 45
36
40
50
60
70
80
100 120 140 14 12,5
FIange 1
C 1 UL udr 140 125 100 90 80 56
C 1 EL udr (C 1 SEL udr) 40 35,5 28 25 22,4 18 16 40
Suessen Toyota Zinser
FIange 1
125 112 90 C 1 UL udr 80 71 50
40 31,5 28 40 31,5
C 1 EL udr (C 1 SEL udr) 25 22,4 20 16 14 12,5 11,2
Rieter Com4
RL dr
ORBIT
SFB 2.8
PM udr/dr 63 45 40 35,5 28
25 22,4 18
16
14 12,5
6
Traveller delivery program for ORBIT and SU rings

ORBIT SFB 2.8
(Subject to modification) Delivery program Most recommended Assignment yarn count /traveller weight see page 4 Traveller Shape Wire type section RL dr PM udr dr ISO numbering (weights in mg)
5 00 90 80 7 6 56 50 45 40 5.5 .5 8 5 .4 0 8 6 4 .5
SU
(Subject to modification) Delivery program Most recommended Assignment yarn count /traveller weight see page 4 Traveller Shape Wire type section SU-B drh r SU-BF f SU-BM udr ISO numbering (weights in mg)
400 55 5 80 50 4 00 80 60 40 5 00 90 80 7 6 56 50 45 40 5.5 .5
Example for placing an order: An order should include the following specifications: Traveller shape Example: C MM Wire section udr Finish Saphir Packaging AP Traveller No ISO 7 Quantity in ' 00
see also: traveller type pages 40, 4; traveller weight page 4; finish page
7
Traveller delivery program for flange rings

Flange 1 and
Flange . mm Subject to modification Delivery program Most recommended Assignment yarn count /traveller weight see page 4 Traveller Shape Wire type section C SEL udr EL f C EL udr dr C SL dr L f udr C UL udr f M f dr udr EM f dr udr C UM udr C LM udr C MM udr C HW dr EM fr C SM fr C SH fr Flange .6 mm Traveller No
4 0 8 6 4 /0 /0 /0 4/0 5/0 6/0 7/0 8/0 0/0 /0 6/0 0/0 4/0 8/0 /0
6/0 4/0
6/0
6/0
9/0
8 5 /0 5 6 5 9/0 4/0
6
C EL C UM
udr udr
8
Traveller delivery program for flange rings

Flange 2
Flange 4.0 mm Subject to modification Delivery program Most recommended Assignment yarn count /traveller weight see page 4 Traveller Shape Wire type section M f dr udr f EM dr r udr C UM dr C MM f H dr fr EH dr C HW dr C f dr r Traveller No
4 0 8 6 4 0 8 6 4 /0 /0 /0 4/0 5/0 6/0 7/0 8/0 0/0 /0

6
6 6 6
80
9
Recommendation for Brcker travellers

T flange, ORBIT, SU
Fibre Yarn count range Flange
M 1 / EM 1 dr C 1 MM udr C 1 HW dr C 1 MM udr M 1 / EM 1 udr C 1 UM udr C 1 LM udr M / EM dr
Cotton
Compact yarns see page 6 coarse Ne 66 medium Ne 40 fine Ne 080 C UM udr super fine Ne 6050 C EL udr C UM udr C 1 UL udr C 1 MM udr C 1 SL dr C 1 SEL udr C UL f L / EL f L udr M / EM udr M / EM f M 2 udr C 2 MM dr C UM udr C 1 SL dr C 1 EL udr C 1 SEL udr EL 1 f C EL dr C UL udr Mf M dr EL f M2f M 2 dr
Flange 1
C LM udr M / EM f
C 2 HW dr H 2 / EH 2 dr
C 2 MM dr M 2 / EM 2 dr C UM udr Hf Mf
Flange 2
Hf C MM dr Cf
ORBIT
SFB 2,8 PM udr SFB ,8 PM dr SFB ,8 RL dr
SFB 2,8 RL dr SFB ,8 PM udr SFB ,8 PM dr
SU Travellers in bold prints are mostly used. Traveller weights see page 4
40
Recommendation for Brcker travellers

T flange, ORBIT, SU
Fibre Yarn count range Flange
M 1 / EM 1 dr C 1 MM udr C 1 UM udr C 1 HW dr C 1 UM udr C 1 MM udr C 1 LM udr M 1 / EM 1 udr M 1 / EM 1 dr C UL udr C SL dr C 1 SH fr C 1 SM fr EM 1 fr
PES/CV/Blends
Core yarns see pages 4, 5 coarse Ne 64 mediumfine Ne 060
PAC
Ne 640
Flange 1
C LM udr
M / EM dr
C 2 HW dr H 2 / EH 2 dr
C 2 MM dr C 2 UM udr M / EM dr
C 2 HW dr H 2 / EH 2 dr H fr C UM udr C MM dr
Flange 2
C UM udr
ORBIT
SU-B drh SU-BM drh
SFB 2.8 PM dr SFB .8 PM udr SFB .8 PM r SU-BF udr SU-B drh SU-BM drh SU-BM drh SU-B drh SU-BF udr
SU
Travellers in bold prints are mostly used. Traveller weights see page 4 PES = Polyester CV = Viscose (Rayon) PAC = Acrylic, Polyacrylic
4
Traveller weights for T flange, ORBIT, SU

Compact yarns see page 36 The traveller weights are determined beside the yarn number by the following parameters: O Yarn twist O Fibre type O Spindle speed O Spinning geometry Small ring diameter Large ring diameter A Knitting A Blends, synthetics A Higher RPM A Small balloon A Large balloon
T flange ORBIT
A Lighter travellers A number heavier travellers A Rather lighter travellers A Lighter travellers A Heavier travellers
SU
Tex
Nm
Ne
T flange Traveller No ISO 505 8050 4080 0040 80 690 507 406 5.550 .545 840 5.5 .48 0.4 60 48 .56 .4 9.
ORBIT PES ISO 505 480 0050 6050 500 8060 8040 6 5680 567 506 4050
SU PAC and CV ISO 505 0080 4000 0060 9040 80 680 507 .56
00 7 59 50 4 6 0 5 0 7 5 0 8.5 7.4 6.6 5.6 5. 4.5
0 4 7 0 4 7 4 40 50 60 68 85 00 0 5 50 80 90 0
6 8 10 12 14 16 20 24 30 36 40 50 60 70 80 90 105 112 132
48 4 9 69 7 4 /0 4/0 5/0 /0 6/0 /0 7/0 4/0 8/0 6/0 0/0 7/0 /0 0/0 4/0 /0 6/0 /0 8/0 4/0 9/0 6/0 /0 9/0
905 80 700 690 457 31.550 2840 2540 2031.5 1825 1622.4 1420 48
The values mentioned above are guiding values. The final traveller number should be selected through trials.
4
Evaluation of traveller weight

The traveller has to balance the yarn balloon. Because the balloon varies from bottom to top on large scale, is the traveller on the bottom rather too light, on the top too heavy. Choosing the correct traveller weight is always a compromise. Measuring the yarn tension on ring spinning frame is not practicable. The best method is to judge the balloon shape. This can be done by a stroboscope but also with a flash light. Insert travellers of two to three consecutive Nos. (weights) after doffing on a few spindles and observe the balloon.

4 5 6
Select the traveller weight at base of cop when the bobbin reaches full diameter (Fig ) Balloon should not touch: O Separators O Tip of tube O When using anti-ballooning rings, lower part of balloon should be slightly bigger in diameter than upper part Balloon should not collapse (double ballooning) When shape of balloon is stable, traveller weight is correct Check balloon at full cop (Fig ): O Balloon should not be too straight Check yarn quality with selected traveller weight
Fig : Cop base with full cop diameter
Fig : Full cop
4
Setting of the traveller cleaner

Flange and Flange 1
b
O Under no circumstances should the traveller touch the cleaner (yarn breaks, ring damage). O By application of different traveller types and/ or numbers, the largest value should be set.
Traveller Type C EL / UM L1 C 1 SEL C 1 SL C 1 UL C 1 MM M 1, EM 1 C 1 UM C 1 EL, EL 1 C 1 LM C 1 HW C 1 SM C 1 SH udr f, udr udr dr f, udr udr f, dr, udr fr udr f, dr, udr udr dr fr fr , ,7 Profile 10/0 ,6 ,6 ,8 ,8 ,8 ,9 ,9 ,7 ,9 ,9 8/0-4/0 ,6 ,0 ,8 ,8 ,8 , , ,7 ,7 , ,
b 3/0-3 , , , ,* , ,0 ,9 , , , 4 * ,6 , , ,5 4,0 ,5 4, 5, ,0 4,0 ,0 4-10 11-16
*C MM : Nr 6 b = ,6 ; Nr 70 b = ,0
b h
Tangential traveller cleaner (Flange 1, udr, dr, f profile only) O Suitable for high speed travellers O Recommended for all compact spinning processes O Advantages: more efficient cleaning of the traveller, prevention of fibre accumulation. O Important: The tangential traveller cleaner must be installed with a distance h = 4,5 mm to the flange crown.
3/0-6 ,4 4-12 ,8
Traveller No Distance b
26/0-11/0 ,8
16/0-6/0 ,0
8/0-1 ,
44

Flange 2
b
O Under no circumstances should the traveller touch the cleaner (yarn breaks, ring damage). O By application of different traveller types and/ or numbers, the largest value should be set.
Traveller Type M2 C 2 UM C 2 MM H2 C 2 HW EM 2 EH 2 Type C2 Profile f, dr, udr udr dr f, dr fr dr f, dr r f, dr Profile f r, dr 7/0 ,7 ,4 6/0-1/0 ,0 ,8 , ,7 ,4 ,0 ,4 1-6 , ,5 11/0 ,9 10/0-4/0 , ,7 ,4 3/0-3 , ,9 ,4 , ,0
b 4-10 ,4 , ,0 ,6 ,5 ,0 ,8 ,4 ,8 7-9 ,7 ,8 , ,0 , ,8 , 10-18 , 4,8 , 20-28 ,8 6,0 ,6 30-35 5,0 6,5 , , , ,6 ,4 11-14 16-20 22-36
Tangential traveller cleaner (Flange 2, udr, dr, f profile only) O Suitable for high speed travellers O Recommended for all compact spinning processes O Advantages: more efficient cleaning of the traveller, prevention of fibre accumulation. O Important: The tangential traveller cleaner must be installed with a distance h = 4,5 mm to the flange crown.
Traveller No Distance b
12/0-4/0 ,8
6/0-8 ,
3-36 4,
45
ORBIT ring/traveller system

T-Ring The ORBIT ring/traveller system (patented world-wide) is designed for spinning at top speeds whilst producing best yarn quality. The special features of the ORBIT system are: O Large contact area between traveller and ring reduces the specific pressure O Optimum heat dissipation traveller to ring The ORBIT system offers the following advantages: O Increase in speed and production O High dynamic stability in traveller running O Reduction of yarn breakage O Improved and more consistent yarn quality O No thermal damage when processing synthetics Application: Fibres: Cotton combed Polyester/cotton blends Polyester 00% Yarn count range: Ne 0 to 60 recommended finer and coarser possible Pre-conditions for best results: O High performance spinning frames O Yarns with warp twist (high strength allows high spinning tension) O Roving yarns in high and even quality O Well performing air-conditioning
ORBIT-Ring
Contact surface
46
Ring travellers for ORBIT rings

Shape Designation Profile ISO number range Application O Cotton O Polyester O Blends medium coarse O Cotton O Blends O Compact yarns Ne 6 and coarser
dr SFB .8 PM udr
.540
880
SFB .8 RL
dr
,57
O Cotton O (Polyester ) O Blends fine yarn counts O Compact yarns Ne 0 and finer
SFB 2.8 PM: for all fibre types, large yarn clearance, therefore especially suitable for manmade fibres. SFB 2.8 RL: small yarn clearance, especially suitable for cotton yarn, good fibre lubrication. Possible to process fine blends (cotton/polyester) and in particular for compact yarns. The travellers for ORBIT rings are used with the well-established Rapid tool (see pages 74, 75). SFB travellers are exclusively supplied in magazined packaging.
Traveller weights/yarn counts see page 4.
47
Traveller wear and tear

Visual assessment
Optimal wear distribution Traveller weight OK
Excessive wear in area B Traveller is too heavy
Excessive wear in area A Traveller is too light
Heavy wear! If more than 0% of the travellers are worn out: O Reduce changing cycle of travellers O Reduce spindle speed O Check the rings O Possibly change traveller shape, wire section or traveller weight
48

Tangential traveller cleaner
b
Guiding value setting b:
4,5 mm Traveller No ISO .540 880 65 b ,5 mm ,9 mm , mm
Caution! Under no circumstances should the traveller touch the cleaner. The traveller number used at the end of the ring running-in program, i.e. also for normal operation, is decisive. Mounting height of the tangential cleaner: 4,5 mm below the ring crown
49
SU ring/traveller system
T-Ring The SU ring/traveller system is suitable for the processing of synthetics (PAC, VC, PES) and their blends in the medium to coarse yarn count range. In some cases the conical, lubricated rings can be replaced by the SU ring/traveller system. The design features of the SU system are: O Large contact area between ring and traveller reduces the specific pressure. O Optimum heat dissipation traveller to ring The SU ring/traveller system provides following advantages: SU O No lubrication required (as against conical rings; not suitable for wool and wool blends) O Better and more even yarn quality O Consistent yarn tension O No thermal fibre damages O Increased life cycle of travellers and rings O Higher spindle speeds O Lower yarn breakage rate O No yarn stain
Contact surface
50
Ring travellers for SU rings

Shape Designation Profile ISO number range Application O Acrylics O Polyester O Blends
SU-B
drh
,5400
SU-BF
udr
,590
O Viscose O Viscose blends O Acrylics O Fibres with strong softening agents
SU-B
5,580
SU-BM
drh
5,54
O Acrylics O Polyester O Blends
SU-B For all synthetics and blends. SU-BF For viscose fibres, higher speeds compared to SU-B and SU-BM SU-BM For all synthetics and blends. Enlarged yarn clearance, especially suitable for delicate fibres. The travellers for the SU-rings are used with the well proven RAPID tool SU (see pages 74, 75). Finish SU travellers are available in SAPHIR, STARLET and PYRIT. Traveller weights/yarn counts see page 4
5

Guiding value setting b:
b
Traveller No ISO < ISO 6 ISO 56 > ISO 00
b ,7 mm ,9 mm , mm
5

Spinning rings
5
Rings, range of application

T flange and ORBIT rings
Weaving yarn
v traveller m/s
Knitting yarn
Yarn count Ne High
ORBIT TITAN
Performance
PlATIN (only 36 to 42) STRATO+

Normal
THeRMO800
PlATIN rings only Flange 1 Fixing systems see page 58
54
Ring profiles
Flange-, ORBIT-, SU-rings

Brcker World Standard for Flange rings. The international Standard for spinning rings ISO 96- specifies inner and seating diameter, ring height and Flange size. The Flange profile (shape) is not specified. In order to make traveller selection (ring/traveller combination) more efficient, Brcker has set with its Flange N98 profile a World Standard. These profiles were introduced in 998. The change was fully concluded in 006. Flange 1 Flange width . mm
Flange N98
Flange 2 Flange width 4.0 mm
Flange N98
ORBIT SFB .8
Orbit with supporting ring
SU
SU with supporting area/-ring
55
Ring shapes
According to ring spinning machine (fixing methods)

Solid rings, Flange 1 and 2 (3.2 and 4.0 mm) Ring finish TITAN, STRATO+, THERMO800 Ring 6, 8, 40, 4, 45, 48, 5, 54, 57 mm (larger on request)
Height 8 mm
mm
8 (9) mm
Ring assembly, Flange (consisting of performance part and ring holder) Details see page 57
Ring finish TITAN PLATIN Flange 1 (3.2 mm) 6, 8, 40, 4, 45, 48 mm 6, 8, 40, 4 mm Flange 2 (4.0 mm) 45 mm
Ring assemblies
Assembly with metal holder (black) max. 45
Assembly with Alu-holder
Assembly Group max. 45
Oblique rings ORBIT/TITAN SU/TITAN
6, 8, 40, 4, 45 mm 4, 45, 48, 5 mm
ORBIT
SU
56
Brcker ring holder Assembly system (two-part rings)

Valuable only for Flange rings in TITAN and PLATIN finish. Every ring spinning manufacturer has its own system for fixing the rings on the ring rails. The ring flange, which is the most important part, is standardized (ISO 96-, see also page 55). The Brcker ring holder system consists of the performance part (flange) and a holder, individually designed to the appropriate ring spinning machine. This allows to maintain the performance part as a standard item. This assemblies are available only in Flange N98 (World Standard see page 55). Performance parts
TITAN
PLATIN
examples (performance part either TITAN or PLATIN)
Assembly with metal foot (black)
Assembly with Alu-holder
Assembly Group with sheet metal holder and traveller cleaner
Fixing methods see page 58
57
Fixing methods
Rings with Assembly system (two-part rings), TITAN and PlATIN
Assembly Group Zinser 5, Chinese ring spinning machines.
Assembly with metal foot (black) Chinese ring spinning machines.
Assembly with Alu-holder Circlip fixation Zinser, Toyota, KTTM
Solid rings, TITAN, STRATO+, THeRMO800
Rieter, Lakshmi ring spinning machines
Circlip fixation Zinser, Toyota, KTTM
58
Start-up proceeding for new rings (Ring running-in)

Ring fixing The rings have to be fixed secure, horizontally and concentric with the spindle. It is not necessary to clean Brcker rings, as the special conservation material helps the start-up of the rings. Should the rings nevertheless be cleaned, use only a dry cloth (do not use any solvents). Running-in procedure (conventional rings) Conventional rings (STRATO+ and THERMO800) must go through a running-in program before starting. By doing this, the ring raceway is being smoothed and passivated (oxidation) through the applied travellers. At the same time the necessary lubrication film coming from wax, softening agents and fibre fragments is being built up. Depending on the spinning fibres, yarn counts and final speed, the spindle speed must be reduced for the first 0 to 0 traveller changes. It is essential that the ring running-in is carried out carefully, as this will improve the general running conditions and in addition it will extend the ring life. Start-up proceeding (for TITAN and PlATIN rings) Under normal condition the TITAN coating can not be affected by the traveller. However, in the first phase, the traveller has to build-up a lubrication film and this depends from the processed fibre material and yarn count. For regular fibres, the start-up proceeding is carried out without reduction of the RPM, only the first traveller change intervals are shortened. For compact yarns and very fine yarns (from Ne 80) a special start-up program must be applied. Selecting travellers The same travellers as for the regular processing can be used. Often, for the first - changes, travellers with a reduced weight are used. Ring load Avoid too heavy loads on the ring running track (see page 6). Traveller wear Avoid heavy traveller wear at start-up and regular running in order to prevent premature ring wear (see also page 6). Running-in program, start-up instruction Instructions corresponding to each Brcker ring type are delivered with each shipment. Upon request, a special adapted program can be provided too. Please contact your local agent. For establishing a running-in program we need the following specifications: O Ring diameter O Ring type, flange size O Fibre type, yarn count, twist O Final speed (RPM) O Presently used traveller (type and weight) O Present traveller life
59
Ring life time

The ring life time depends on various parameters. The following table explains the correlation. Attention: An accumulation of causes is possible. TITAN rings are less sensible and have generally a very long life time. A ring replacement is advisable, when the desired yarn quality can not be achieved any more.
Parameter Cotton Fibre Man made Softening agents Yarn count Yarn Twist Shape Traveller Life time Traveller speed Performance Ring running-in Spinning geometry Climatic conditions Centring Machines Vibration Fibres Chlorine Strong Danger None, low Too short Too long High Right Normal As per instruction Larger Dry Dull Aggressive Coarse Warp High-bowed Ring stress High wax proportion Bright Lubricating Fine Knit Low-bowed Remarks High wax proportion increases the traveller lubrication Dull fibres include abrasive particles (e.g. Titan oxide) Influence on traveller lubrication Higher load on heavier traveller Warp yarns are spun with heavy travellers, therefore higher load and lower traveller lubrication (lower hairiness). Better traveller lubrication with low-bowed travellers Heavy worn-out travellers damage the traveller raceway of the rings (see also page) Higher load at high speeds (see Ring load page) Ring running-in must be carried out according to the fibre and ring type. TITAN rings need merely a start-up proceeding. The centrifugal force of the traveller is higher on small ring diameters and therefore leads to a higher ring load. An irregular climate has a negative influence on the general running behaviour and therefore leads to a higher ring load. Badly centred rings, anti-ballooning rings and thread guides produce irregular loads. Inconsistent loads lead to premature wear and tear. Fibres containing chlorine may damage also coated (TITAN, PLATIN) rings Chlorine contaminated water must be avoided
Ring diameter
Smaller
Irregular Poor
Constant Good
Air condition and Danger spinning environment
60
Influence of the ring condition on the yarn quality

The ring/traveller system has to fulfil the following functions: O To transmit the twist O To provide and regulate the spinning tension O To wind up the yarn The spinning tension is a central factor for the yarn quality regarding yarn hairiness. The most important influencing parameters for a consistent spinning tension are: O Centring of the ring to the spindle O Centring of the thread guides and antiballooning rings O Surface condition of the ring raceway
Influence of different surface conditions on the yarn hairiness

Ring condition Roughness values Achieved yarn quality Ne 60132 Ne 2450 Ne 620
Rt RzD Ra
0 ,0 0 ,0 0 0,5
Rt RzD Ra
,0 ,5 ,0 ,5 0,5 0,
Rt RzD Ra
,5 ,0 ,5 ,0 0,0 0,5
Rt RzD Ra
,0 4,0 ,0 ,0 0,5 0,40
Rt RzD Ra
> 4,0 > ,0 > 0,40
Good
Acceptable
Critical
Deficient
6
Traveller wear, insufficient lubrication

In order to prevent premature ring wear check the traveller wear rate and traveller wear pattern at running-in and normal operation. With this two parameters one can judge if the ring load is within the limits and fibre lubrication is sufficient.
Normal traveller wear Working condition ok.
excessive traveller wear If more than 0% of checked travellers show heavy wear, reduce spindle speed until normal traveller wear is achieved.
Abnormal traveller wear If abnormal wear is noticed, reduce spindle speed. Insufficient fibre lubrication causes a wear pattern as shown in the picture above.
liability Brcker takes no liability for damaged rings when the previous described instructions were not followed. This for the running-in as well as for regular operation.
6
Ring load
Maximum ring load In order to prevent any damage of the coated rings (TITAN, PLATIN), one should not exceed the ring load as indicated in the diagram/table below. Brcker takes no liability for damaged rings if the recommended loads have been exceeded.
6'000 5'000 Load in mN 4'000 3'000 2'000 Ring inner diameter in mm Cotton Pes/Blends 54 5000 6000 5 4850 5800 48 4650 5600 45 400 500 4 4000 4800 40 600 4400 8 50 4000 6 900 600
Maximum ring load in mN
Formulas
Ring load
2 L = m*v r
Maximum spindle speed RPMmax = L*d 60 * 1000 m * 2 * d * 3.14
L m v r
= = = =
ring load in mN traveller weight in mg traveller speed in m/s ring radius in mm (ring-/)
L = ring load in mN m = traveller weight in mg d = ring- in mm
Ring loads can also be seen on tables pages 65 to 7 Traveller wear see page 6 Start-up instruction (ring running-in) see page 59
6
Ring load tables

Select ring inner diameter and traveller no (weight) to get the ring load created by the traveller.
Ring 36
Traveller RPM 13'000 13'500 14'000 14'500 15'000 15'500 16'000 16'500 17'000 17'500 18'000 18'500 19'000 19'500 20'000 20'500 21'000 21'500 22'000 22'500 23'000 23'500 24'000 24'500 25'000 No m/s 4 5 6 7 8 9 0 4 5 6 7 8 9 40 4 4 4 44 45 46 47 '99 '70 4'7 576 65 676 79 784 84 640 694 75 80 87 77 778 84 800 868 12/0 11/0 10/0 18 20 22.4 8/0 25 7/0 28 6/0 5/0 4/0 40 3/0 45 2/0 50 1/0 56 1 63 2 71 3 80 4 90 6 100 '00 '47 '756 4'050 4'56 4'67 5'000 5'9 5'689 5'689 6'050 6'4 6'806 7'00 7'606 8'0 8'450 8'889 9'9 9'800 7 112 '584 '889 4'06 4'56 4'878 5' 5'600 5'980 6'7 6'7 6'776 7'9 7'6 8'064 8'58 8 125 4'000 4'40 4'694 5'06 5'444 5'840 6'50 6'674 7' 7' 7'56 8'08 8'507 9'000 9'507 Traveller Weight 31.5 35.5 Ring load in mN 896 '008 '6 '80 '440 '600 '79 '06 '7 '560 '880 97 '094 ' '89 '56 '76 '944 '88 '465 '778 '5
99 '05 '8 ' '50 '690 '878 '0 '66 '666 '004 '80
907 '0 '4 '76 '48 '60 '8 '05 '68 '55 '876 '40 '645 976 '089 '0 '7 '546 '74 '960 '78 '49 '744 '09 '484 '90
94 '047 '68 '08 '47 '659 '869 '0 '6 '66 '944 '7 '78 4'05
900 '000 '0 '50 '400 '575 '775 '000 '50 '500 '800 '50 '550 4'000 4'500 96 '068 '96 '5 '495 '68 '895 '6 '40 '669 '990 '64 '79 4'7 4'805 '04 '8 '74 '4 '59 '79 '00 '76 '560 '844 '86 '584 4'09 4'55 5'0 '04 '8 '74 '4 '59 '79 '00 '76 '560 '844 '86 '584 4'09 4'55 5'0 '089 '0 '55 '5 '694 '906 '48 '40 '7 '05 '88 '8 4'96 4'840 5'445 '56 '84 '49 '606 '798 '0 '80 '569 '890 ' '596 4'046 4'560 5'8 5'780 '5 '6 '54 '70 '906 '44 '46 '7 '06 '40 '8 4'88 4'8 5'444 6'5 '96 '440 '6 '800 '06 '68 '556 '880 '40 '600 4'0 4'56 5' 5'760 6'480 '69 '5 '704 '90 '0 '96 '700 '04 '4 '80 4'59 4'79 5'400 6'084 6'845 '444 '604 '797 '006 '46 '57 '848 '09 '60 4'0 4'49 5'054 5'696 6'48 7'0 '5 '690 '89 ' '66 '66 '000 '80 '80 4'5 4'7 5'4 6'000 6'760 7'605 '600 '778 '99 ' '489 '800 '56 '556 4'000 4'444 4'978 5'600 6' 7' 8'000 '68 '868 '09 '5 '65 '94 '5 '76 4'0 4'669 5'0 5'884 6'6 7'47 8'405 '764 '960 '95 '450 '744 '087 '479 '90 4'40 4'900 5'488 6'74 6'958 7'840 8'80
8'985 0'08 9'464 0'56 9'956 ' 0'460 '674 0'976 '50
'849 '054 '0 '568 '876 '6 '647 4'09 4'6 5'6 5'75 6'47 7'9 8'8 9'45 0'7 '505 '840 '96 '5 '409 '689 '0 '88 '88 4'0 4'840 5'78 6'0 6'776 7'66 8'604 9'680 0'756 '046 '444 '05 '50 '50 '8 '50 '544 '994 4'500 5'06 5'65 6'00 7'088 7'988 9'000 0'5 '50 '600 4'06 '6 '5 '6 '99 '9 '70 4'7 4'70 5'90 5'878 6'58 7'406 8'46 9'404 0'580 '756 '66 4'694 '09 '454 '749 '068 '46 '866 4'57 4'909 5'5 6'6 6'87 7'7 8'7 9'88 '045 '7 '745 5'40
max. load for cotton max. loads for Pes/Blends too high load, danger for ring damage
64
Ring load tables

Ring 38
Traveller RPM 13'000 13'500 14'000 14'500 15'000 15'500 16'000 16'500 17'000 17'500 18'000 18'500 19'000 19'500 20'000 20'500 21'000 21'500 22'000 22'500 23'000 23'500 24'000 24'500 25'000 No m/s 5 6 7 8 9 0 4 5 6 7 8 9 40 4 4 4 44 45 46 47 48 49 '99 '70 4'7 59 640 69 74 797 85 658 7 767 85 885 77 797 859 8 889 12/0 11/0 10/0 18 20 22.4 8/0 25 7/0 28 6/0 5/0 4/0 40 3/0 45 2/0 50 1/0 56 1 63 2 71 3 80 4 90 '96 '0 '45 '74 '984 4'6 4'55 4'85 5'58 5'476 5'80 6'9 6'485 6'840 7'05 7'579 7'96 8'56 8'758 6 100 '89 '558 '87 4'6 4'46 4'77 5'058 5'89 5'7 6'084 6'447 6'8 7'05 7'600 8'005 8'4 8'847 7 112 '684 '985 4'97 4'6 4'957 5'05 5'665 6'06 6'49 6'84 7' 7'640 8'070 8'5 8 125 4' 4'447 4'796 5'58 5'5 5'9 6' 6'77 7'64 7'605 8'059 8'56 9'007 9'500 Traveller Weight 31.5 35.5 Ring load in mN 9 '06 '68 '6 '480 '645 '84 '07 '6 '6 996 ' '6 '4 '60 '779 '99 '4 '56 '846
959 '074 '09 '6 '55 '77 '98 '49 '47 '74 '069
94 '0 '55 '00 '465 '65 '857 '06 ' '600 '90 '0 99 '07 '9 '94 '57 '77 '99 ' '479 '789 '4 '54
947 '06 '84 '6 '49 '68 '895 ' '68 '65 '984 '6 '789
90 '0 ' '64 '46 '59 '796 '0 '76 '59 '8 '86 '59 4'046 970 '078 '07 '47 '509 '698 '9 '56 '45 '695 '08 '95 '87 4' '0 '46 '84 '4 '605 '805 '05 '9 '579 '866 '0 '6 4'069 4'585 '095 '7 '6 '5 '704 '97 '60 '44 '78 '04 '407 '8 4'0 4'867 '6 '89 '444 '6 '805 '0 '89 '579 '90 '4 '6 4'06 4'578 5'58 '8 '64 '58 '705 '90 '49 '4 '78 '069 '4 '80 4'97 4'84 5'457 '97 '44 '64 '80 '07 '70 '558 '88 '4 '60 4'05 4'59 5'6 5'764 '68 '50 '70 '900 '8 '94 '698 '040 '40 '800 4'56 4'788 5'96 6'080 '44 '60 '79 '00 '4 '5 '84 '0 '60 4'00 4'48 5'04 5'684 6'404 '56 '684 '886 '05 '58 '65 '989 '68 '789 4' 4'76 5'05 5'979 6'77 '59 '769 '98 ' '477 '787 '4 '59 '98 4'44 4'955 5'574 6'8 7'078 '67 '857 '080 ' '600 '95 '96 '74 4'78 4'64 5'99 5'849 6'59 7'47 '75 '946 '80 '4 '75 '065 '455 '89 4'79 4'866 5'450 6' 6'909 7'785 '84 '08 '8 '547 '85 '0 '67 4'076 4'585 5'095 5'706 6'49 7'5 8'5 '98 ' '87 '664 '984 '57 '784 4'6 4'796 5'9 5'968 6'74 7'567 8'56
8'966 0'007 9'4 0'56 9'909 '059
9'84 0'98 '605 9'7 0'899 '64
9'7 0'89 '4 '77 9'59 0'658 '97 '
'005 '7 '495 '784 '8 '508 '954 4'455 5'0 5'568 6'7 7'06 7'907 8'909 0'0 '7 '47 '9 '09 '5 '604 '907 '55 '66 4'7 4'65 5' 5'8 6'5 7'5 8'55 9'0 0'464 '66 '0 4'5 '8 '45 '76 '0 '95 '80 4'05 4'85 5'457 6'06 6'79 7'640 8'60 9'70 0'94 '6 '58 5'58 '75 '57 '8 '59 '58 '98 4'486 5'055 5'687 6'8 7'077 7'96 8'97 0'09 '7 '67 4'5 5'796
65
Ring load tables

Ring 40
Traveller RPM 13'000 13'500 14'000 14'500 15'000 15'500 16'000 16'500 17'000 17'500 18'000 18'500 19'000 19'500 20'000 20'500 21'000 21'500 22'000 22'500 23'000 23'500 24'000 24'500 25'000 No m/s 7 8 9 0 4 5 6 7 8 9 40 4 4 4 45 46 47 48 49 50 5 5 '99 '70 4'7 656 706 757 80 865 79 784 84 86 878 12/0 11/0 10/0 18 20 22.4 8/0 25 7/0 28 6/0 5/0 4/0 40 3/0 45 2/0 50 1/0 56 1 63 2 71 3 80 4 90 '8 '58 '785 4'050 4'5 4'608 4'90 5'0 5'5 5'8 6'6 6'498 6'845 7'00 7'565 7'98 8' 6 100 '645 '90 4'05 4'500 4'805 5'0 5'445 5'780 6'5 6'480 6'845 7'0 7'605 8'000 8'405 8'80 7 112 4'08 4'90 4'70 5'040 5'8 5'74 6'098 6'474 6'860 7'58 7'666 8'086 8'58 8 125 4'556 4'900 5'56 5'65 6'006 6'400 6'806 7'5 7'656 8'00 8'556 9'05 9'506 Traveller Weight 31.5 35.5 Ring load in mN 9 '0 '48 '94 '458 '640 '8 '04 '96 '588 '96 980 '098 '5 '9 '568 '764 '960 '95 '470 '78 '6
94 '05 '77 '5 '49 '68 '89 '0 '55 '649 '986 '64
900 '008 '5 '60 '48 '598 '800 '05 '50 '50 '85 '95 '600 96 '076 '0 '45 '54 '706 '9 '6 '40 '69 '07 '4 '844
9 '04 '47 '80 '44 '6 '88 '048 '04 '560 '867 '6 '65 4'096 980 '089 '0 '6 '55 '75 '9 '78 '450 '7 '049 '40 '866 4'56 '040 '56 '95 '445 '68 '8 '05 ' '60 '890 '7 '64 4'04 4'64 '0 '5 '7 '5 '75 '99 '74 '450 '756 '06 '40 '859 4'49 4'900 '66 '96 '45 '60 '84 '04 '00 '59 '96 '40 '69 4'08 4'60 5'84 ' '69 '5 '7 '97 '56 '40 '78 '080 '4 '8 4' 4'860 5'476 '00 '444 '67 '805 '0 '74 '56 '888 '49 '60 4'04 4'549 5'6 5'776 '69 '5 '704 '90 '9 '96 '700 '04 '4 '80 4'59 4'79 5'400 6'084 '440 '600 '79 '000 '40 '50 '840 '00 '600 4'000 4'480 5'040 5'680 6'400 '5 '68 '88 '0 '5 '648 '984 '6 '78 4'0 4'707 5'95 5'968 6'74 '588 '764 '976 '05 '470 '778 ' '58 '969 4'40 4'99 5'557 6'6 7'056 '664 '849 '07 ' '589 '9 '8 '698 4'60 4'6 5'77 5'84 6'564 7'96 '8 '05 '68 '5 '85 '89 '594 4'050 4'556 5'06 5'670 6'79 7'89 8'00 '904 '6 '70 '645 '96 ' '756 4' 4'76 5'90 5'95 6'665 7'5 8'464 '988 '09 '474 '76 '09 '479 '9 4'48 4'970 5'5 6'85 6'958 7'84 8'86
8'960 0'000 9'44 0'506 9'878 '05
9'45 0'54 '556
9' 0'5 '40 '656 9'5 0'580 '850 '5 9'94 '045 '70 '806
'074 '04 '580 '880 '6 '69 4'090 4'608 5'84 5'760 6'45 7'58 8'79 9'6 0'68 '50 '90 4'400 '6 '40 '689 '00 '6 '78 4'6 4'80 5'40 6'00 6'7 7'56 8'54 9'604 0'805 '005 '446 5'006 '50 '500 '800 '5 '500 '98 4'48 5'000 5'65 6'50 7'000 7'875 8'875 0'000 '50 '500 4'000 5'65 '4 '60 '9 '5 '64 4'097 4'67 5'0 5'85 6'50 7'8 8'9 9'4 0'404 '705 '005 4'566 6'56 '44 '704 '08 '80 '786 4'59 4'800 5'408 6'084 6'760 7'57 8'58 9'599 0'86 '68 '50 5'4 6'900
66
Ring load tables

Ring 42
Traveller RPM 10'500 11'000 11'500 12'000 12'500 13'000 13'500 14'000 14'500 15'000 15'500 16'000 16'500 17'000 17'500 18'000 18'500 19'000 19'500 20'000 20'500 21'000 21'500 22'000 22'500 No m/s 4 5 6 7 8 9 0 4 5 6 7 8 9 40 4 4 4 45 46 47 48 49 '99 '70 4'7 60 686 744 805 868 705 768 8 794 864 8/0 25 7/0 28 6/0 5/0 4/0 40 3/0 45 2/0 50 1/0 56 1 63 2 71 3 80 4 90 6 100 7 112 8 125 9 140 10 160 11 180 Traveller Weight 31.5 35.5 Ring load in mN 894 '008 '4 '60 '4 '587 '789 '05 '67 '59 974 '097 '4 '7 '56 '78 '947 '94 '469 '74 '8 '49 '57 4'00 4'54 '07 '49 '840 4'89 4'97 ' '70 4'67 4'76 5'57 '605 4'04 4'507 5'50 5'794 '888 4'9 4'860 5'554 6'49 4'8 4'667 5'7 5'97 6'70 4'485 5'006 5'607 6'408 7'09 4'800 5'57 6'000 6'857 7'74 5'5 5'70 6'407 7' 8'7 5'46 6'095 6'87 7'80 8'777 6'65 6'88 7'707 8'808 9'909 6'5 7'9 8'67 9' 0'500 6'9 7'74 8'640 9'874 '09 7'0 8'49 9'7 0'40 '74 7'70 8'595 9'67 '00 '77 8' 9'054 0'40 '589 '07 8'5 9'54 0'667 '90 '74 8'965 0'006 '07 '808 4'409 9'408 0'500 '760 '440 5'0 9'86 '006 '7 4'088 5'849
98 '057 '90 '9 '488 '667 '875 ' '8 '679 '976
90 '04 '4 '88 '449 '60 '80 '08 '86 '575 '897 '9 97 '094 ' '89 '56 '76 '944 '87 '465 '777 '4 '47
9 '045 '76 '5 '49 '680 '867 '09 '5 '65 '987 '60 '7 '00 ' '6 '4 '60 '80 '00 '4 '5 '84 '04 '604 4'005 '07 '00 '50 '5 '74 '99 '4 '400 '700 '04 '49 '857 4'86 '44 '8 '44 '65 '80 '059 '88 '56 '88 '49 '66 4'9 4'576 '9 '65 '56 '7 '950 '94 '48 '7 '07 '46 '90 4'89 4'876 '76 '54 '74 '954 '0 '477 '75 '08 '468 '908 4'404 4'954 5'505 '458 '6 '88 '07 ' '65 '97 '67 '675 4'4 4'667 5'50 5'8 '54 '78 '944 '9 '469 '777 '086 '456 '888 4'8 4'97 5'554 6'7 '60 '85 '054 '4 '608 '94 '60 '65 4'07 4'69 5'5 5'867 6'59 '79 '95 '66 '44 '750 '094 '48 '85 4' 4'88 5'50 6'89 6'876 '8 '08 '8 '57 '897 '59 '6 4'056 4'56 5'4 5'794 6'59 7'4 '905 ' '400 '705 '048 '49 '80 4'67 4'800 5'40 6'095 6'857 7'69 '00 '4 '5 '84 '0 '60 4'00 4'48 5'04 5'68 6'404 7'04 8'005 '00 '5 '646 '98 '60 '780 4'00 4'704 5'9 5'964 6'70 7'560 8'400 '0 '465 '774 '6 '5 '96 4'40 4'9 5'547 6'5 7'044 7'94 8'805
'4 '700 '08 '4 '857 4'9 4'8 5'400 6'075 6'846 7'74 8'679 9'64 0'800 '054 '500 5'49 7'57 '59 '8 '74 '577 4'00 4'54 5'08 5'64 6'48 7'54 8'06 9'069 0'076 '85 '595 4'07 6' 8'7 '60 '945 '4 '74 4'08 4'74 5'60 5'89 6'67 7'469 8'45 9'467 0'59 '78 '49 4'77 6'80 8'94 '74 '07 '456 '895 4'89 4'97 5'486 6'44 6'9 7'790 8'777 9'874 0'97 '88 '74 5'60 7'554 9'749 '858 '0 '60 4'059 4'57 5'45 5'77 6'40 7'0 8'8 9'47 0'90 '4 '805 4'9 6'007 8'9 0'580
67
Ring load tables

Ring 45
Traveller RPM 8'000 8'500 9'000 9'500 10'000 10'500 11'000 11'500 12'000 12'500 13'000 13'500 14'000 14'500 15'000 15'500 16'000 16'500 17'000 17'500 18'000 18'500 19'000 19'500 20'000 No m/s 8 0 4 5 7 8 9 0 4 5 6 7 8 40 4 4 4 44 45 47 '99 '70 4'7 576 7 784 860 648 800 88 70 889 806 4/0 40 3/0 45 2/0 50 1/0 56 1 63 2 71 3 80 4 90 6 100 7 112 8 125 9 140 10 160 11 180 12 200 13 224 14 250 16 280 Traveller Weight Ring load in mN 907 '0 '5 '96 '440 '6 '800 '06 '04 '59 '880 '6 '600 4'0 996 '0 '6 '4 '600 '778 '99 ' '489 '844 '00 '556 '98 4'444 4'978
980 '098 '5 '9 '568 '764 '960 '95 '450 '744 '6 '58 '90 4'90 4'900 5'488
968 '076 '05 '55 '57 '7 '96 '5 '409 '689 '0 '44 '87 4'0 4'88 5'78 6'0
940 '058 '76 '7 '48 '669 '88 '6 '5 '6 '99 '9 '76 4' 4'70 5'66 5'878 6'58 '04 '5 '80 '44 '6 '88 '048 '04 '560 '867 '00 '584 4'096 4'608 5'0 5'74 6'400 7'68 ' '50 '89 '556 '750 '97 ' '500 '778 ' '47 '889 4'444 5'000 5'556 6' 6'944 7'778 '96 '458 '60 '84 '04 '00 '59 '96 '40 '69 4'050 4'56 5'84 5'8 6'480 7'58 8'00 9'07 '94 '568 '74 '95 '95 '474 '788 '6 '484 '90 4'56 4'878 5'575 6'7 6'969 7'805 8'7 9'756 '495 '68 '869 '09 '55 '654 '990 '64 '78 4'86 4'67 5' 5'980 6'78 7'476 8'7 9'44 0'466 '600 '800 '000 '40 '50 '840 '00 '600 4'000 4'480 5'000 5'600 6'400 7'00 8'000 8'960 0'000 '00 '708 '9 '6 '9 '69 '0 '47 '844 4'7 4'784 5'9 5'980 6'84 7'688 8'54 9'567 0'678 '959 '80 '048 '76 '549 '867 ' '64 4'096 4'55 5'097 5'689 6'7 7'8 8'9 9'0 0'94 '78 '74 '055 ' '569 '877 '7 '648 4'0 4'64 5'8 5'754 6'4 7'9 8'0 9'48 0'76 '509 '844 4'86 '78 '450 '7 '049 '40 '866 4'56 4'900 5'444 6'098 6'806 7'6 8'7 9'800 0'889 '96 '6 5'44 '04 '59 '880 '6 '69 4'090 4'608 5'84 5'760 6'45 7'00 8'064 9'6 0'68 '50 '90 4'400 6'8 '44 '78 '04 '407 '8 4'0 4'868 5'476 6'084 6'85 7'606 8'58 9'75 0'95 '69 '69 5' 7'06 '567 '888 '09 '594 4'04 4'557 5'4 5'776 6'48 7'88 8'0 8'985 0'68 '55 '86 4'76 6'044 7'970 '844 '00 '556 '98 4'480 5'049 5'689 6'400 7' 7'964 8'889 9'956 '78 '800 4' 5'99 7'778 9'9 '988 '6 '76 4'84 4'707 5'04 5'977 6'74 7'47 8'68 9'9 0'460 '954 '448 4'94 6'75 8'678 0'99 '6 '58 '90 4'90 4'99 5'566 6'7 7'056 7'840 8'78 9'800 0'976 '544 4' 5'680 7'56 9'600 '95 '87 '698 4'09 4'60 5'77 5'85 6'574 7'96 8'8 9'04 0'7 '505 '48 4'79 6'46 8'408 0'544 '00 '44 '87 4'0 4'88 5'4 6'09 6'884 7'744 8'604 9'67 0'756 '046 '767 5'488 7'09 9'74 '5 4'09 '600 4'050 4'500 5'040 5'670 6'90 7'00 8'00 9'000 0'080 '50 '600 4'400 6'00 8'000 0'60 '500 5'00 '97 4'48 4'909 5'498 6'85 6'97 7'854 8'86 9'88 0'996 '7 '745 5'708 7'67 9'66 '99 4'544 7'490
68
Ring load tables

Ring 48
Traveller RPM 6'500 7'000 7'500 8'000 8'500 9'000 9'500 10'000 10'500 11'000 11'500 12'000 12'500 13'000 13'500 14'000 14'500 15'000 15'500 16'000 16'500 17'000 17'500 18'000 18'500 No m/s 6 7 8 0 5 6 7 8 0 5 6 7 8 40 4 4 4 45 46 '99 '70 4'7 47 48 540 667 75 807 88 480 54 608 750 87 5 60 675 8 597 674 756 67 759 85 757 855 85 4/0 40 3/0 45 2/0 50 1/0 56 1 63 2 71 3 80 4 90 6 100 7 112 8 125 9 140 10 160 11 180 12 200 13 224 14 250 16 280 '987 '7 '780 4'667 5'45 5'647 6'7 7'9 7'887 8'505 9'47 Traveller Weight Ring load in mN 960 '067 '95 ' '49 '707 '90 ' '89 '667 96 '084 '04 '49 '505 '686 '97 '68 '408 '697 '00
959 '080 '5 '50 '5 '688 '890 '60 '40 '700 '04 '75
9 '050 '8 ' '500 '667 '867 '08 ' '667 '000 ' '7 4'67
99 '09 '58 '05 '470 '654 '88 '058 '97 '57 '940 '08 '675 4'6 4'594
908 '008 '9 '7 '4 '6 '85 '07 '59 '5 '8 '7 '60 4'0 4'57 5'04 99 '0 '4 '89 '565 '76 '984 '04 '469 '755 '086 '57 '968 4'408 4'97 5'50
'04 '7 '0 '458 '64 '849 '08 '44 '604 '97 '55 '646 4'67 4'688 5'08 5'8 6'50 '7 '68 '408 '577 '775 '000 '5 '55 '87 '55 '5 '94 4'507 5'070 5'6 6'09 7'04 '5 '67 '59 '70 '94 '57 '40 '74 '08 '40 '797 4'5 4'860 5'468 6'075 6'804 7'594 '07 '470 '6 '89 '058 '9 '6 '940 '67 '659 4'08 4'57 5'7 5'880 6'5 7'7 8'67
'500 '688 '875 '00 '6 '66 '000 '75 '750 4'00 4'688 5'50 6'000 6'750 7'500 8'400 9'75 0'500 '60 '80 '00 '4 '5 '84 '0 '604 4'004 4'485 5'005 5'606 6'407 7'08 8'008 8'969 0'00 ' '707 '90 ' '89 '688 '09 '4 '840 4'67 4'779 5' 5'97 6'87 7'680 8'5 9'557 0'667 '947 '85 '04 '69 '54 '859 ' '60 4'084 4'58 5'08 5'67 6'5 7'60 8'68 9'075 0'64 '44 '705 '04 '97 '55 '858 '6 '64 4'08 4'594 5'04 5'77 6'80 7'46 8'67 9'88 0'08 '4 '760 4'9 '60 '40 '700 '04 '40 '84 4'0 4'860 5'400 6'048 6'750 7'560 8'640 9'70 0'800 '096 '500 5'0 '8 '567 '85 '94 '594 4'050 4'56 5'4 5'704 6'89 7'0 7'986 9'7 0'68 '408 '777 4'60 5'97 '407 '708 '008 '69 '79 4'7 4'8 5'45 6'07 6'79 7'5 8'4 9'67 0'80 '0 '477 5'04 6'847 '667 '000 ' '7 4'00 4'7 5' 6'000 6'667 7'467 8' 9' 0'667 '000 ' 4'9 6'667 8'667 '80 '5 '50 '9 4'4 4'97 5'60 6'04 7'004 7'845 8'755 9'806 '07 '608 4'008 5'689 7'50 9'6 '940 '08 '675 4'6 4'6 5'9 5'880 6'65 7'50 8' 9'88 0'90 '760 '0 4'700 6'464 8'75 0'580 '08 '467 '85 4'4 4'854 5'470 6'6 6'94 7'704 8'69 9'60 0'786 '7 '868 5'408 7'57 9'60 '57 '75 '797 4'9 4'75 5'6 5'99 6'750 7'594 8'48 9'450 0'547 '8 '500 5'88 6'875 8'900 '094 '65 '57 '968 4'408 4'97 5'555 6'60 7'05 7'95 8'87 9'875 '0 '4 4'07 5'870 7'6 9'749 '04 4'687
69
Ring load tables

Ring 51
Traveller RPM 6'000 6'250 6'500 6'750 7'000 7'250 7'500 7'750 8'000 8'250 8'500 8'750 9'000 9'250 9'500 9'750 10'000 10'250 10'500 10'750 11'000 11'250 11'500 11'750 12'000 No m/s 6 6 7 8 8 9 0 0 4 4 5 6 6 7 8 8 9 0 0 '99 '70 4'7 56 56 65 7 7 79 878 878 6 6 74 800 800 7 7 805 80 80 1/0 56 1 63 2 71 3 80 4 90 6 100 7 112 8 125 9 140 10 160 11 180 12 200 13 224 14 250 16 280 '8 '8 '7 '558 '558 '964 4'9 4'9 4'84 5'5 5'5 5'809 6'5 6'5 6'86 7'4 7'4 8'005 8'609 8'609 18 315 '6 '6 '570 4'00 4'00 4'459 4'94 4'94 5'448 5'979 5'979 6'55 7'5 7'5 7'7 8'5 8'5 20 355 '564 '564 4'0 4'5 4'5 5'06 5'569 5'569 6'9 6'78 6'78 7'65 8'09 8'09 8'70 24 400 4'06 4'06 4'5 5'08 5'08 5'66 6'75 6'75 6'98 7'59 7'59 8'98 9'05 9'05 9'804 Traveller Weight Ring load in mN 904 '004 '4 '55 '405 '606 '807 '008 '49 '50 904 '004 '4 '55 '405 '606 '807 '008 '49 '50
907 '00 ' '69 '47 '587 '8 '040 '67 '59 '8
90 '06 '44 '7 '4 '588 '779 '0 '87 '54 '846 '76 90 '06 '44 '7 '4 '588 '779 '0 '87 '54 '846 '76
89 '005 ' '74 '46 '586 '770 '98 '65 '548 '8 '7 '59 988 '4 '55 '4 '569 '757 '96 '96 '50 '84 '7 '54 '9 988 '4 '55 '4 '569 '757 '96 '96 '50 '84 '7 '54 '9
968 '090 '8 '84 '556 '79 '97 '6 '4 '767 ' '459 '874 4'4 '06 '96 '48 '58 '708 '898 '6 '7 '657 '07 '46 '796 4'5 4'745 '06 '96 '48 '58 '708 '898 '6 '7 '657 '07 '46 '796 4'5 4'745 '6 '07 '47 '660 '867 '075 ' '59 '904 '9 '74 4'49 4'647 5'86 '65 '4 '604 '807 '0 '59 '50 '84 '6 '64 4'066 4'58 5'060 5'647 '65 '4 '604 '807 '0 '59 '50 '84 '6 '64 4'066 4'58 5'060 5'647 '7 '544 '740 '96 '06 '45 '745 '064 '4 '9 4'4 4'90 5'490 6'7 '485 '670 '88 ' '86 '65 '969 '4 '7 4'4 4'77 5'0 5'98 6'67 '485 '670 '88 ' '86 '65 '969 '4 '7 4'4 4'77 5'0 5'98 6'67 '60 '80 '00 '87 '57 '859 '0 '574 4'00 4'574 5'46 5'78 6'404 7'47 '7 '97 '8 '460 '767 '075 '44 '84 4'04 4'99 5'54 6'49 6'887 7'686 '7 '97 '8 '460 '767 '075 '44 '84 4'04 4'99 5'54 6'49 6'887 7'686 '847 '078 '4 '68 '968 '98 '694 4' 4'67 5'77 5'96 6'596 7'88 8'45 '976 '4 '506 '84 '76 '59 '95 4'4 4'94 5'647 6'5 7'059 7'906 8'84 '976 '4 '506 '84 '76 '59 '95 4'4 4'94 5'647 6'5 7'059 7'906 8'84
9'4 0'604 9'4 0'604
9'005 0'49 '45 9'685 0'95 '98 9'685 0'95 '98
9'5 0'89 '708 '9 9'88 '8 '59 4'8 9'88 '8 '59 4'8
'0 '74 '676 '05 '9 '769 4' 4'7 5'76 6'00 6'784 7'57 8'44 9'4 0'55 '87 '79 5'075 '49 '50 '85 ' '64 4'06 4'498 5'00 5'6 6'45 7'8 8'0 8'995 0'09 '44 '649 4'56 6'06
70
Ring load tables

Ring 54
Traveller RPM 5'000 5'250 5'500 5'750 6'000 6'250 6'500 6'750 7'000 7'250 7'500 7'750 8'000 8'250 8'500 8'750 9'000 9'250 9'500 9'750 10'000 10'250 10'500 10'750 11'000 No m/s 4 4 5 6 6 7 8 9 9 0 4 4 5 6 6 7 8 8 9 0 '99 '70 4'7 407 407 467 5 5 599 67 749 749 80 457 457 55 597 597 674 756 84 84 55 55 59 67 67 760 85 58 58 667 759 759 856 65 65 750 85 85 76 76 8 8 8 1/0 56 1 63 2 71 3 80 4 90 6 100 7 112 8 125 9 140 10 160 11 180 12 200 13 224 14 250 16 280 18 315 '87 '87 '65 '987 '987 '7 '780 4' 4' 4'667 5'45 5'45 5'647 6'7 6'70 6'70 7'9 7'887 7'887 8'505 9'47 9'47 9'8 20 355 '577 '577 '958 '66 '66 '800 4'60 4'746 4'746 5'59 5'798 5'798 6'64 6'955 7'57 7'57 8'8 24 400 '904 '904 ' '79 '79 4'8 4'800 5'48 5'48 5'96 6'5 6'5 7'70 7'87 8'5 8'5 9'59 Traveller Weight Ring load in mN 907 '06 '6 '07 '45 '66 '85 '0 907 '06 '6 '07 '45 '66 '85 '0
9 '04 '67 ' '500 '667 '867 '08 '
948 '06 '85 '7 '57 '707 '896 '4 '70 '655 948 '06 '85 '7 '57 '707 '896 '4 '70 '655
96 '070 '99 '8 '499 '7 '97 '4 '98 '676 '997
960 '080 '00 '44 '500 '680 '90 '60 '400 '688 '000 '60
949 '070 '0 '7 '497 '67 '87 '9 '407 '674 '995 '4 '744 949 '070 '0 '7 '497 '67 '87 '9 '407 '674 '995 '4 '744
9 '05 '85 ' '48 '659 '85 '074 '70 '667 '96 '9 '704 4'48
95 '09 '60 '07 '470 '6 '89 '04 '87 '6 '940 '67 '659 4'08 4'57 95 '09 '60 '07 '470 '6 '89 '04 '87 '6 '940 '67 '659 4'08 4'57 '004 '9 '7 '44 '6 '79 '008 '4 '50 '868 '7 '585 4'05 4'48 5'09 '097 '4 '9 '567 '76 '959 '94 '449 '74 '5 '57 '99 4'89 4'898 5'486 '95 '44 '55 '707 '90 ' '89 '667 '987 '4 '840 4'67 4'779 5' 5'97 '95 '44 '55 '707 '90 ' '89 '667 '987 '4 '840 4'67 4'779 5' 5'97 '96 '458 '644 '85 '08 '5 '59 '894 '4 '704 4'67 4'60 5'85 5'787 6'48 '40 '577 '778 '00 '5 '504 '804 '0 '505 4'006 4'507 5'007 5'608 6'59 7'00 '40 '577 '778 '00 '5 '504 '804 '0 '505 4'006 4'507 5'007 5'608 6'59 7'00 '5 '70 '97 '60 '40 '700 '04 '75 '780 4'0 4'860 5'400 6'048 6'750 7'560 '66 '89 '06 ' '6 '904 '5 '60 4'065 4'646 5'7 5'807 6'504 7'59 8'0 '66 '89 '06 ' '6 '904 '5 '60 4'065 4'646 5'7 5'807 6'504 7'59 8'0 '744 '96 ' '49 '80 '5 '489 '894 4'6 4'984 5'607 6'0 6'977 7'787 8'7
8'888 0'05 8'888 0'05 9'585 0'800 0'08 '65 0'08 '65 '058 '459
'867 '00 '67 '667 '000 ' '7 4'67 4'667 5' 6'000 6'667 7'467 8' 9' 0'500 '8 ' '99 '4 '57 '847 '0 '559 '986 4'449 4'98 5'695 6'407 7'9 7'97 8'898 9'966 ' '65 4'7
7
Designation of the ring parts, example for placing an order

A B C D D D E F G H I K L M Inner diameter Fitting diameter Shoulder diameter (largest outer diameter) Ring height Height above ring rail Height below ring rail Flange (see page 55) Flange width Flange crown Outer flange radius Raceway of ring Web Shoulder Slot for circlip
H G D F I E K L B D M A
example for placing an order; request for a quotation The following specifications are required: see page Ring type Brcker Flange width Flange profile Inner diameter Fitting diameter Shoulder diameter (largest ) Ring height Ring fixation Machine type 54 55 55 Example Titan Flange , . mm Normal, N98 4 mm 49 mm 5 mm 8 mm Circlip Zinser 0
58
O Please send a ring sample for any new enquiry or order. O For repeat orders previous corresponding invoice number or ring drawing is sufficient.
7

Inserting Tools
7
Inserting tools for magazined travellers

Brcker RAPID for C-shaped, ORBIT and SU travellers Characteristics O Slender and easy to use tool, specially suited to small gauges or when ring data is installed. O Possible threading the yarn in the traveller when inserting O Simple setting with traveller as a gauge O Ergonomically simple, untiring inserting Range of applications see page 75
RAPID AP (magazined systems see page 77)
RAPID STRAP (magazined systems see page 77)
74
RAPID inserting tools for magazined travellers

Range of applications
One tool for each type of traveller. Exchange of storing bar not possible.
Wire section Traveller shape Traveller No range 1) Brcker L1 M 1, EM 1 C 1 EL, EL 1 C 1 UL C 1 SL C 1 UM C 1 LM C-shaped f, dr, udr C 1 MM C 1 HW C1 M 2, EM 2 H 2, EH 2 C 2 UM C 2 MM C 2 HW C2 EM 1 C-shaped fr all all C 1 SM C 1 SH, H 2 SU-B, -BM, -BF SFB 2.8 PM, RL AP STRAP all all 8/0 alle all all all all alle /0 all 6/06 74 all all all 4/06 7 66 6/06 70 all all all all all ISO all all all alle all all all all alle 87 600 all .500 50 all all all 4000 00 0045 .500 55 all all all all all Tool No RAPID 400 679.xxx 40/40* 408 44/44* 424/425* 49/40* 4/44* 44/45* 405 424/425* 47 48 646 448 447 60/60* 67 6 60 6 646 67 66 409 76 9/70 85 86/86* Storing bar Profile 679.252.xx .0 .0 .05 .07 .0 .0 .07 .07 .0 .0 .5 . .7 .5 .5 .55 .5 .5 .5 .7 .75 .04 .55 .5 679.54 679.55
* Fine version: for travellers 8/0, ISO 5 and lighter ) for heavy travellers (above No 0, ISO 60) use Brcker BOY. Availability of magazined travellers according to delivery program.
75
Brcker BOY
The conventional tools are preferred (only AP magazined) for special applications and when the use of RAPID becomes impossible.
Type C8 C9 C 7 C 7 Flange 1 (3.2mm) 2 (4.0mm) 1 (3.2mm) 2 (4.0mm) Inserting of travellers from outside to inside from inside to outside (for ring M 48mm)
76
Magazining systems
Brcker AP (Automatic Packing) O Magazining system for C-shaped travellers O Flexible system for easy handling O Traveller designation (type and No) on AP rod (to avoid mix-ups)
Brcker STRAP O The traveller is taken up on a profile STRAP, up to 0'000 per spool O STRAP system for: O ORBIT travellers O SU travellers O C-shaped travellers with fr-Profile
Availability for magazined travellers according to delivery program.
77
Brcker RAPID
Profit when using Brcker RAPID for traveller change The Brcker RAPID provides following advantages: O Fast and easy inserting of travellers O Reduced labour costs O Shorter idle times of machines, therefore higher production O Threading during traveller change possible O No traveller losses O Minimal traveller deformation O Easy tool adjustment O Suitable for small spindle gauges
Increase if production/Year by using the RAPID '000
8'000 kg 4'000
0
0 Number of spinning frames
0
Calculation base: Ne 0, 0,5 TPI, 7'000 RPM Spinning machine with '080 spindles, 5 traveller changes per year Time for inserting travellers: with RAPID sec./by hand sec
78
Traveller inserting and removing tools

ClIx O For inserting (loose) and removing the following travellers: O C-shaped O ORBIT O SU
OUTY O For removing C-shaped and ORBIT travellers O Removed travellers are collected in the handle
Type 0 0 0 Traveller type Flange (. mm) High-performance travellers Flange (4.0 mm) High-performance travellers ORBIT travellers
79
80
BERKOL
8
BERKOL top roller covers

One of the main tasks of a spinning mill is to manufacture yarns of excellent quality as economically as possible. For this reason, the top roller cover amongst numerous other factors deserves a special attention because the right choice of quality influences the profitability of the spinning mill to a very large degree. Experience has shown that purchasing cheap top roller covers can seldom be justified economically. Because only the best quality ensures in the medium- and long-term that yarn is manufactured in a consistently high quality. Spindle downtimes are also reduced by having fewer thread breakages and laps. On the basis of these facts, we have for years been concentrating on the development and production of high-quality top roller covers. Only first-class raw materials are used, processed with state-of-the-art production methods. Exact checks ensure that the high standard of BERKOL covers is consistently maintained. The raw material Compounds on the basis of nitrile butadiene rubber in the hardness range of approx. 65 to 8 Shore A are used as coating raw materials. The composition of the raw material determines the characteristics of the cover such as O Hardness O Elasticity O Grip O Abrasion resistance O Notch-tensile strength O Swelling resistance O Color These characteristics should fulfil the following demands made on a top roller cover: O Good fiber guiding O No lap formation O Long working life O Good ageing stability O Minimal film formation
8
Product qualities of BERKOL top roller covers

Material Colour HardResistance to Physical properties ness Finishing Ageing, Elasticity Lap Abrasion Mechanical Permanent Shore A agent, temperaformation resistance load deformation grease, oil ture capacitiy 67 67 68 70 74 80 66 78 good satisfactory not tested not tested
HA 65 S HA 67 T
brown orange
HA 65 A light red HA 70 T dark blue HA 74 T dark green HA 80 OE HA 65 D HA 75 D excellent yellow black black
very good
Selection of the top roller cover The demands made on top roller covers have risen enormously in the last few years. The continually increasing quality requirements and the higher processing speeds mean that great attention must be paid to the right choice of covers with regard to lap formation, working life, swelling, ageing as well as static charge. The quality of the rubber covers should not be determined only in the light of the above mentioned characteristics, but also depend on the machine type, the climatic conditions and the yarn quality. This is why it is so important to take the advice of the cover manufacturer. Full certainty in the choice of the optimal cover quality for your special requirements can be gained through practical spinning tests in your plant.
8
BERKOL Rubber qualities

Fibre quality Carded Combed Blended yarns/ Wool cotton cotton Synth. fibres Drawing frame HA 65 S HA 65 S HA 80 OE HA 80 OE HA 80 OE HA 80 OE HA 74 T HA 74 T HA 74 T HA 65 S Combing machine detaching roller delivery roller HA 80 OE drawing system HA 65 S HA 80 OE Roving frame/speed frame/finisher HA 70 T HA 70 T HA 80 OE HA 80 OE HA 74 T HA 74 T HA 74 T HA 80 OE HA 80 OE HA 70 T HA 80 OE Ring spinning machine HA 65 A HA 65 A HA 74 T HA 67 T HA 67 T HA 80 OE HA 70 T HA 70 T HA 74 T HA 74 T HA 65 A HA 80 OE HA 80 OE HA 67 T Rotor spinning machine HA 80 OE HA 80 OE HA 80 OE HA 74 T HA 74 T HA 74 T Texturizing machine Type of machine
Synth. fibre Technical Filaments long staple fibres HA 80 OE HA 80 OE
HA 80 OE HA 80 OE HA 74 T HA 80 OE HA 80 OE HA 74 T HA 70 T
HA 65 D HA 74 D
84
The BERKOL Alupress cover

New methods for the assembly of the rubber tube and the arbor had to be sought because of the increasing strain on the top rollers due to higher speeds, pressing-down forces and temperature. The solution is BERKOL Alupress. The Alupress cover consists of a precise Aluminium tube, which the rubber is vulcanised onto. Technical advantages O The rubber coating is vulcanised on stressfree, eliminating the danger of an ozone crack. O The connection between the tube and the rubber guarantees perfect adhesion even with great strain and at high temperatures. O The Alupress can be pressed onto the top roller easily and fast. O Ensure adhesion of the Alu tube on the top roller. economic advantages O No tiresome sticking, it is simply pressed on saving time and cost. O No waiting time, the cover can be ground immediately after pressing. O No cleaning required when replacing the cover. The Alupress covers can be pressed on with manual, pneumatic or hydraulic presses onto the arbors. The BERKOL presses guarantee exact guiding and positioning of the cover.
85
Available BeRKOl Alupress dimensions and corresponding arbor diameters

Arbor , length m 40 mm 6,0 7,0 8,0 9,0 ,0 ,0 6,0 0,0 45,0 50,0 60,4 Alutube inside 5,88 6,85 7,85 8,87 ,9 ,9 5,9 9,85 44,90 49,90 60,8 Arbor , length M 40 mm 5,9 6,9 7,9 8,9 ,0 ,0 6,0 0,0 45,0 50,0 60,4
Process of top roller arbors for mounting Alupress covers

Polished surface N5
Buffed
0. A
86
Grinding
The quality of the cover can only be ensured for its entire life if it is maintained properly. Regular grinding is part of this, optimal surface roughness and if necessary surface treatment of the freshly ground covers. The result of optimal care: O Perfectly smooth running O Minimum lap formation O Lower thread break rate The grinding interval is determined by O The deterioration of yarn quality (CV%, IPI) O The increase in the thread break rate O The wear and tear of the cover (rut formation) O Film formation with resulting lap formation Besides the cover quality, the grinding intervals are determined mainly by the application and the quality demands of the customer. Years of experience and in-depth talks with customers have shown that each spinning mill must develop and define their own optimal values. The information in the following table is therefore to be considered only as a guidance:
Application Ring spinning machine delivery top roller
Cover type Yarn count range Grinding interval h Up to 70 Shore A Fine 50750 7075 Shore A 500000 76 Shore A and up 000500 The grinding intervals for the Up to 70 Shore A Medium 000500 feed top rollers can be doubled 7075 Shore A 50750 76 Shore A and up 75050 Up to 70 Shore A Coarse Not recommended 7075 Shore A 000500 76 Shore A and up 50750 Covers from 70 Shore A and up are recommended for the delivery top roller of compact spinning machines. For softer covers, 00% shorter grinding intervals must be adhered to. Roving frame delivery top rollers Up to 70 Shore A 500000 7075 Shore A 000500 76 Shore A and up 5004000 Drawing frame Up to 70 Shore A 500750 7075 Shore A 500750 76 Shore A and up 550750 67 Shore A 500 Combing: detaching roller drafting system 67 Shore A 500 delivery top rollers 808 Shore A 500 (check) Open end spinning machine 80 Shore A 500 delivery roller
87
Grinding
The grinding depth depends on the wear and tear of the cover, we recommend 0.0. mm in diameter. Depending on the application, an additional surface treatment may be advisable. For this, Berkolizing (exactly defined UV-radiation) has been proven and tested for decades. It is easy, inexpensive and environmentally friendly. The optimal surface roughness depends on the cover material, the application and the climate. It has in particular an influence on the lap formation tendency of the cover. Good results were obtained with an average roughness (Ra) between 0.6 and 0.9 . In order to obtain a defined surface roughness, the following factors are decisive: O Grinding machine O Type of grinding disc O Trimming of grinding disc O Settings of grinding machine Roughness values and roughness classes
Roughness value Ra Roughness class m (micrometer) in (microinch) N 50 000 5 000 N 500 N 0 .5 6. 50 N9 5 N8 . 6 N7 .6 0.8 N6 N5 0.4 6 0. 8 N4 4 N 0. 0.05 N 0.05 N lap rate in % 00
50
Polyester/8 ShA 0 fine medium surface structure rough
Influence of the surface roughness on lap formation tendency
For grinding the top rollers, BERKOL offers universal manual grinding machines or fully automatic grinding systems of modular design with integrated surface treatment.
88
BERKOL circular grinding machine Type BGU
BGU with top roller grinding attachment
The manual BERKOL grinding machine Type BGU is suitable for grinding all types and brands of top rollers used in a spinning mill. The precision guides with dust-tight covers guarantee a long life and minimum maintenance. With the specially developed grinding stone and versatile setting possibilities, the desired surface roughness can be attained without any problem. A balancing device for the grinding stone is integrated in the machine. A number of special tools are available for the various top rollers. A dust extractor is included in the scope of supply.
Technical data: Center distance Max. grinding length Max. diameter Spindle speed Installed load Dust extraction Space requirement Weight
650 mm 600 mm 40 mm stepless 50900 rpm 5.0 KW/400 V 0 m/Min. xm 495 kg
89
BERKOL grinding system BGS
BERKOL grinding system with Berkolizing module
The BERKOL grinding system is a modular construction designed for automatic grinding and Berkolizing of ring spinning and roving frame top rollers. The basic machine can be supplied in accordance with customer requirements with modules for measuring the covers, with large magazines (up to 0 top rollers) and with Berkolizing modules. The measuring system offers different measuring and sorting programmes, thus ensuring an efficient quality control of the top rollers. Thanks to the specially developed grinding stone and the versatile setting possibilities, optimal roughness values can be obtained. All models of the machine have a high output to deal with 00 top rollers per hour. The dust extraction device is included in the scope of supply.
Technical data: Max. top roller length Cover diameter Max. cover length Extraction Installed load Compressed air connection Max. air consumption Space requirement Weight, depending on model
90 mm 440 mm 60 mm 0 m/min. 5.6 KW/400 V 60 bar 50 L/Min. .0 x . m 550790 kg
90
The surface treatment

Laps can form on the top roller covers depending on the fiber material being processed, the climate and the spinning machine. To avoid these laps, the covers used to be treated with lacquers, hydrochloric acid solutions, iodine and similar. These treatments are time-consuming, expensive and frequently environmentally harmful. Sometimes they even corrode the metal. Nowadays, these agents tend to be avoided. They have been almost completely replaced by surface treating by means of UV-radiation, socalled Berkolizing. The treatment is applied after grinding the covers, providing artificial ageing of the rubber surface and reducing the abrasion coefficient. Even with regular application, the cover material does not become either hard or damaged. But optimal dosage of the radiation time is very important for success. This process has the following advantages: O Easy and fast O Inexpensive O Environmentally friendly Our customers obtain the following advantages from Berkolizing: O Reduction of the run-in problems of newly ground covers O Good running properties O Better yarn quality O Less labour requirement O Cost reduction The duration of the Berkolizing is decisive for success. It should always be as short as possible. Berkolizing for too long reduces the friction coeficient of the covers wich leads to thread breaks. The duration of the treatment depends on: O application (ring spinning, combing, etc.) O climate O fiber material O cover properties O type of Berkolizing machine The wide range of these influencing factors shows that each customer has to define the optimal Berkolizing time through trials. In the Instruction Books for the manual and automatic Berkolizing machines, BERKOL gives recommendations and standard values for the relevant applications.
Berkolized
unberkolized
9
The new manual Berkolizer 06 machine

O Simultaneous berkolizing and loading of top rollers, thanks to a revolving drawer, increases the efficiency in the roll shop O Especially developed 000 watt UV lamp and reflectors guarantees short exposure of cots due to highly concentrated and even irradiation intensity O Long life and efficiency of UV lamp is strongly enhanced due to the un-interrupted running of the Berkolizer, due to minimal heat build up properties of the UV lamp O Lower energy consumption and low maintenance cost reduce operating costs considerably O Compact and user friendly design O A small investment with very high benefits O Environment friendly and proven process to improve the perfomance of any cots
Berkolizer 06
Berkolizing top rollers influences the running charateristics of spinning machines positively in many aspects. However, berkolization cannot improve a poor cot quality and poor finish. Perfect fine buffing is absolutely essential before berkolizing, as well as the time of berkolizing the top rollers.
9
Top roller size testing device

Concentricity tester Even yarn of top quality can only be spun with perfectly smooth-running top rollers. BERKOLs testing devices are crucial for quality assurance. They reveal faults, thus helping to save money. The top roller testing device from BERKOL is for checking the parallelism and smooth running of all the top rollers of a spinning mill. The BERKOL testing device is a precision instrument. It is delivered in a solid, practical hardwood box which protects the device from dust and dirt. Measuring range: Roller diameter Max. roller length Measuring sensor Pitch 0 to 00 mm 450 mm 0.8 mm 0.0 mm
The hardened and ground contact rollers are driven by a smooth-running electro motor. The freely moving measuring carriage runs on a precision guide, free of play. The spherical joint supports allow fast, exact positioning of the precision measuring sensors. Faults concerning smooth running, parallelism or wear and tear can be measured with 0.0 mm accuracy.
9
Surface finish measuring device

Roughness tester The surface texture has a great influence on the running behaviour of the top roller covers. It can be checked with the lip, with a magnifying glass or with a surface finish measuring device. A surface finish measuring device has the great advantage that the coarseness can be quantified and documented with a measured value. The perthometer which BERKOL supplies is particularly suitable for measuring soft materials.
Shore hardness testing device

HPSA R 35 M The hardness of top roller covers has a great influence on the draft performance and thus on the yarn quality. It is usually measured in Shore A. The standard measurement in accordance with DIN 5505 prescribes a coating thickness of minimum 5 mm and a press-on force of kg. The measurement on a drum therefore usually differs from the effective value. The BERKOL hardness checking device is fitted with an appliance which shows the right press-on force.
94
Lubrication
Technical progress in a modern spinning mill with high performance machines and a reduced number of staff needed to run them, requires rational maintenance of all production machines and appliances. In close cooperation with users, we have developed efficient lubrication appliances which surpass conventional manual devices by far. Regular lubrication considerably lengthens the working life of the bearings. BeRKOlUBe Up to 800 top roller bearings for ring spinning machines or roving frames can be lubricated per hour with this pneumatic lubrication device which ensures an exact dosage of the required amount of grease. Various take-up tools and lubrication nozzles are available to adapt to the different top roller types. The device can be adjusted very quickly to the various top roller types. The BOS-0 is an inexpensive manual lubrication device for all axially-lubricated top rollers. The standard equipment is suitable for top rollers with a tube diameter of 9 mm and a maximum length of 80 mm. Appropriate tools can be provided for other top roller types. Technical Data: O Amount of grease per bearing adjustable from 0. to .0 cm O Capacity of 600 to 800 top rollers per hour O CE-conforming with pneumatic two-hand safety control O A 5 kg grease container is sufficient for 0'000 to '000 top rollers
BERKOLUBE
Lubricating device BOS-0
95
LUBRIBOY
This mobile lubrication device was developed especially for spinning mill requirements. Using its compressed air tank, it can be run independent of external pipes and cables. One compressed air filling of 0 bar is sufficient for hundreds of lubrication jobs. The grease is carried to the lubricating pistols using air motors. The high-pressure lubricating pistol produces a grease pressure of over 00 bar, making it suitable for lubrication of all bearing positions in the spinning mill. The amount of grease is adjustable to the requirements of the spinning mill and can be set in the range of 0. to 0.7 cm. A mechanical display allows the monitoring of the grease flow. A flexible tube is included, to be used for lubrication points which are difficult to reach.
The lubricating pistol, developed especially for drawing system bearings, has the following features: O Stepless setting of the amount of lubricant from 0.08 to 0.4 cm O Monitoring of the grease flow using illuminating diodes ensures precise, targeted lubrication O Adjustment of the pressing-in speed to the bearing speed O Grease pressure approx. 50 bar In this way, grease does not escape from the needle bearings so much less cleaning is required. Costly bearing damage can be avoided.
Summary The BERKOL servicing machines and devices feature a solid, durable construction and requires minimum maintenance. In addition, BERKOLs excellent After Sales Service is also at your disposal. Brcker is worldwide the only company which, under the brand name BERKOL, supplies top roller covers and machines for their maintenance from own production.
96
BERKOL PU aprons
Polyurethane is a highly abrasion- and ozone resistant material. BERKOL has utilised these particular characteristics and has developed a single-layer, seamless PU apron. BERKOL PU aprons are used only as top apron and achieve in combination with rubber or leather bottom aprons excellent yarn values. Your advantages: O Substantial longer life time than classical rubber aprons O Long shelf life as a result of the ozone resistance O Excellent and steady performance throughout the whole running time
97
98
Tools
99
Cleaning tools
Fluff removers for cleaning of textile machines

ROlSPRINT Technically advanced tool with gears of hardened steel and special easy running ball bearings. Exchangeable tip. Standard spindle lengths: 00/5/400/500
ROlTex Simple, reliable tool. Ball bearing with free running. Spindle made of anti-magnetic steel. Exchangeable tip. Standard spindle length: 00/5/400 mm Special spindle length:500/60/800 mm
00
Cutting tools
Brcker cutting tools for the application in various spinning mill departments. SeCUTex O Safety cutter with blade protection O Exchangeable steel blade
CUTex O Tuft cutter with brass blade (exchangeable) O different blade lengths
0
0
Yarn carriers
0
Gretener High-tech yarn carriers for high-speed spinning and roving machines
Spinning tubes for the production of quality yarns at highest speeds require top quality in design, raw material and manufacturing. Gretener spinning tubes and roving bobbins are exclusively made from first garde compounds and are produced with state-of-the-art technology. They meet highest quality levels in dimension, concentricity, run out stability and deformation. They comply with ISO 68 standard. Only the combination of top quality spindles and tubes guarantees highest performance. Brcker manufactures tubes and bobbins for high-end spinning machines such as RIETER, ZINSER, TOYOTA, MARZOLI. Summary of spinning tube materials
ABS RPM Steamable Mechanical stability Impact strength Run-out tolerances (ISO 68) Ferrules Application/ discharge force ABS PC < 8'000 no good sufficient < 0.5 mm optional < 15 N* ABS with Delrin bush < 8'000 no good sufficient < 0.5 mm optional < 15 N PC < 5'000 0 C very good very good < 0.5/0. mm optional > 15 N PC with sliding bush < 5'000 no very good good < 0.5/0. mm optional < 15 N* PC with Delrin bush < 5'000 0 C very good good < 0.5/0. mm optional > 15 N
Acrylnitril-Butadien-Styrol Polycarbonat
* suitable for RIETER ROBOdoff
04
Special tubes for ZINSER and TOYOTA ring spinning machines

Tubes in ABS or Polycarbonate (PC) with Delrin high-resistant bush to prevent premature wear through spindle clutch.
High-resistant Delrin bush
High-tech spinning tubes for RIETER spinning machines (G30, G33, G35, K44, K45)
For these high-speed machines with automated doffing system, RIETER requests pull off force lower than 5 N in order to ensure trouble-free doffing. The compound PBT guarantees the excellent gliding properties but has not the requested stability. The Gretener solution Combining the Polycarbonate (PC) with outstanding stability and PBT with best gliding properties. The spinning tube of two compounds fulfils all requirements.
PBT bush for excellent gliding properties
Polycarbonate (PC) for outstanding stability
05
Index
Page 86 14 77 97 86 86 90 91 95 32 96 76 89 100 79 36 93 28 34 101 101 3739 72 19 21 58 6, 16, 63 87 2830 74, 76, 79 62 96 96 77 92 26 31 4652 4649 79 2831 74 14 40, 41 60 63 55 59 56 Page 61 38, 39 37 37 54 54 100 100 94 104 18 101 84 44, 45 49 52 94 15 54 104, 105 77 5052 88 91 90 89 83 95 87 21 22, 23 26, 27 3741 16 48 62 17 42, 43 38,39 37 37 104, 105 20 20 104, 105 24, 25 6, 7 2830 2831, 61
Alupress dimensions Anti-ballooning ring AP (Automatic Packing) Aprons Arbor dimensions Arbor requirements for mounting Alupress Automatic grinding system Berkolizing Berkolube Blended and synthetic yarns Bottom roller lubrication Brcker BOY Circular grinding Cleaning tools CLIx Compact Spinning Concentricity tester Cop hairiness Core yarns CUTEx Cutting tools Delivery program travellers Designation of ring parts Designation of traveller parts Finishing treatments Fixing methods rings Formulas Grinding interval Hairiness Inserting + removing tools Insufficient lubrication Lubriboy Lubrication pistols Magazining systems Manual Berkolizer Motions of the ring traveller Neps Oblique flange rings ORBIT ring/traveller system OUTY Quality (yarn) RAPID Inserting tools Ratio ring / tube Recommendation for travellers Ring life time Ring load Ring profiles Ring running-in Ring shapes
Ring surface condition Ring travellers flange Ring travellers for ORBIT rings Ring travellers for SU rings Rings Rings application ROLSPRINT ROLTEx Roughness tester Roving bobbins Security SECUTEx Selection of top roller covers Setting of the traveller cleaner flange Setting of the traveller cleaner ORBIT Setting of the traveller cleaner SU Shore hardness tester Spinning geometry Spinning rings Spinning tubes STRAP SU rings and travellers Surface roughness Surface treatment Technical data, automatic grinder Technical data, circular grinder Top roller cover qualities Top roller lubrication Top roller maintenance Traveller finishing treatment Traveller friction Traveller position Traveller shape Traveller speeds Traveller wear and tear ORBIT / SU Traveller wear flange Traveller weights, comparison Traveller weights, evaluation Travellers for flange rings Travellers for ORBIT rings Travellers for SU rings Tubes Wire sections Yarn breaks Yarn carriers Yarn clearance Yarn count numbering Yarn hairiness Yarn quality
07
Brcker AG Obermattstrasse 65 8330 Pfffikon-Zrich Switzerland Phone +41 44 953 14 14 Fax +41 44 953 14 90 sales@bracker.ch
Brcker S.A.S. 132, rue Clemenceau 68920 Wintzenheim France Phone +33 3 89 27 00 07 Fax +33 3 89 27 52 30 sales@bracker.fr Brcker S.R.L. Via Garodino Zona Industriale 28075 Grignasco Italy Phone +39 0163 411 294 Fax +39 0163 418 989 sales@bracker.it
www.bracker.ch
STOZ / 04.08

Short Staple Spinning: Bräcker AG Bräcker S.A.S

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Short Staple Spinning

For Your Profit

Knowledge Experienced industry professionals Competence in advising and providing solutions

Rings and Travellers C-shape ORBIT and SU travellers

Rings and Travellers Spinning rings

Rings and Travellers Inserting tools

Tools Yarn carriers Index

pages 99-101 pages 103-105 page 107

Technical spinning information

Numbering systems for yarns and twists

tex 0, dtex

Nm 000 tex 0000 dtex 9000 den ,69 NeC

NeC 590 tex 5900 dtex 55 den

NeL 654 tex 6540 dtex 488 den

NeW 98 tex 980 dtex 7440 den

NeK 886 tex 8860 dtex 797 den

0,605 NeL 0,57 NeL

,7 NeL 0,56 NeL 0,457 New

0,56 New 0,05 New 0,85 New

,9 NeK 0,667 NeK ,867 NeK ,88 NeK

Twist with Ne T/ = ae Ne with Nm T/m = am Nm with tex T/m = atex tex

NeL NeW NeK

Weft twist Knit twist

p Warp x 0,9 p Warp x 0,8

Numbering systems for yarns and twists

Distribution of yarn breaks while building up of the cop

Causes of yarn breaks

Breakage during doffing

Example of annual loss in production due to yarn breaks

Production/spindle/hour in grams 5.8 .7 5.7 10 min. 8'000

Average duration of breakage: Hours of operation in 1 year:

Ne 20 Annual loss in production by '000 spindles in tons

Breakage rate per '000 spindles/hour

C-shape, ORBIT and SU travellers

Rings and Travellers

Requirements for optimum results with Brcker rings and travellers

Relation yarn count/ring diameter/flange type/traveller speed

Traveller speeds/performance calculations

Feet/min: ~ m/s x 00

Spindle speed n/min

Spindle speed n/min

= Delivery in m/min. = Spindle speed in min-

Traveller weights comparison chart flange travellers

35.5 (5/0) 5. (5/0)

* Only coated travellers, main types

Utilize eye protection

Designation of the ring traveller parts

drh half round high

SFB travellers: udr, dr profile.

0.09 0. 0. Coefficient of friction e

Yarn clearance and its influence on the traveller lubrication

vertical (theoretical position)

Motions of the ring traveller

Spinning on empty tube: a large Bottom of taper

Spinning on full cop: a small

Ring traveller/ring contact areas

Hairiness measuring methods see page 0.

O Increase traveller weight or choose another traveller type

O No remedy possible, however, improve general running behaviour

Wear and tear area

Processing of blended and synthetic yarns

Special attention Travellers Shape Wire section Weight

tex 0, dtex

Nm 000 tex 0000 dtex 9000 den ,69 NeC

NeC 590 tex 5900 dtex 55 den

NeL 654 tex 6540 dtex 488 den

NeW 98 tex 980 dtex 7440 den

NeK 886 tex 8860 dtex 797 den

0,605 NeL 0,57 NeL

,7 NeL 0,56 NeL 0,457 New

0,56 New 0,05 New 0,85 New

,9 NeK 0,667 NeK ,867 NeK ,88 NeK

Production/spindle/hour in grams 5.8 .7 5.7 10 min. 8'000

Ne 20 Annual loss in production by '000 spindles in tons

Breakage rate per '000 spindles/hour

Feet/min: ~ m/s x 00

= Delivery in m/min. = Spindle speed in min-

35.5 (5/0) 5. (5/0)

0.09 0. 0. Coefficient of friction e

Hairiness measuring methods see page 0.

55 5 5 50 4 00 60 40

40 00 9 7 9 6 8

80 40 5

5/0 0/0 /0 /0

8 5 /0 5 6 5 9/0 4/0

C 2 MM dr M 2 / EM 2 dr C UM udr Hf Mf

SFB 2,8 PM udr SFB ,8 PM dr SFB ,8 RL dr

SFB 2,8 RL dr SFB ,8 PM udr SFB ,8 PM dr

00 7 59 50 4 6 0 5 0 7 5 0 8.5 7.4 6.6 5.6 5. 4.5

0 4 7 0 4 7 4 40 50 60 68 85 00 0 5 50 80 90 0

Fig : Cop base with full cop diameter

Fig : Full cop

*C MM : Nr 6 b = ,6 ; Nr 70 b = ,0

dr SFB .8 PM udr

Traveller weights/yarn counts see page 4.

4,5 mm Traveller No ISO .540 880 65 b ,5 mm ,9 mm , mm

Traveller No ISO < ISO 6 ISO 56 > ISO 00

b ,7 mm ,9 mm , mm

ORBIT SFB .8

6, 8, 40, 4, 45 mm 4, 45, 48, 5 mm