Dr.

B R Ambedkar National Institute of Technology

Jalandhar

Presentation
on

AUTOCONER 21C

Madan Regar
M.Tech
(Textile Engineering and Management)
Department of Textile Technology
 WINDING

Ring spinning produces yarn in a package form called cops. Since cops from
ringframes are not suitable for further processing, the winding process serves to
achieve additional objectives made necessary by the requirements of the
subsequent processing stages.
Following are the tasks of winding process
Extraction of all disturbing yarn faults such as the short, long thick , long
thin, spinners doubles, etc.
Manufacture of cones having good drawing - off properties and with as long
a length of yarn as possible
paraffin waxing of the yarn during the winding process
introduction into the yarn of a minimum number of knots
achievement of a high machine efficiency i.e. high production level
Main Specifications
Maximum winding speed 2,000 m/min
Balloon control : Bal-Con (brush type kink preventers integrated type)
Tension control : Tension manager
Drum drive : DBL motor (direct drive)
Drum : * Pac21 (100 parallel drum), It is designed to support P
winding, parallel winding, Q winding, and soft winding. 2.0 W
and 2.5 W possible (6-inch traverse), High-speed unwinding
to avoid ribbon winding (pattern winding)
Winding angle : 3 30, 4 20, 5 57, 0
Traverse length : 108 mm (4 inches), 152 mm (6 inches)
Splicer : Cassette type, VOS communication type
Cradle : It is designed to support P winding, Q winding, and
parallel winding (bearing center: optionally available).
Contact pressure : Contact pressure control device by compressed air
(group-by group)It is designed to support soft winding.
Residual yarn feeler : Photoelectric feeler compatible with colored yarn
Tension release : Electrical tension release
Blower system Equipped with power-saving inverter
Winding unit Each winding unit has error/problem indicating function provided
Other optionally available functions:-

* Auto Doffer (AD) (with automatic threading function)

* Package conveyor (Maximum load: 180 kg)
* Blow cleaner
* Hairiness-reducing device
* Waxing device (reverse/forward rotation)
* 3-tier nozzle splicer
* Water splicer
* Splicer for high-twisted yarn
* Bobbin stripper
* Dust collector
* Bracket for lighting equipment
* Centralized suction blower
* Fisherman knitters (quick change type)
AUTOCONER 21C Magazine Type
[1] Bobbin length is 280 mm or less
AUTOCONER 21C Magazine Type
[2] Bobbin length is 281 mm or more
AUTOCONER 21C
[3] Bobbin Tray Type and Link Coner Type
 Bal-Con (Bobbin Tray Type)

Mechanism :- Bal-Con is intended to keep the winding tension at a

constant level throughout the operation of winding yarn from the spinning
bobbin to a full package. Bobbin tray type Bal-Con is integrated with a
kink preventer. It includes a fixed Bal-Con part, movable Bal-Con part,
sensor, air cylinder, and brush.
Operation of the Kink Preventer and Bal-Con
(1) The brush on the kink preventer holds the top of the bobbin during splicing, preventing kinks
from occurring (see the upper figure on the right).
(2) When the yarn starts running after it has been spliced, the kink preventer opens and Bal-Con
lowers.
(3) When the sensor detects the bobbin chase*1, Bal-Con stops lowering.
*1 See the lower figure on the right. The top of the bobbin is tapered to facilitate
unwinding the yarn.
(4) As the yarn from the bobbin is wound onto the package, the bobbin chase lowers.
(5) When the sensor detects the lowering bobbin chase, Bal-Con also
lowers again.
(6) If the yarn breaks during winding, or when the winding has been
completed, Bal-Con returns to its upper end position (home position).
Tensioner & Pre-clearer
It is possible to perform winding with a constant winding
tension all the time by controlling the tensor solenoid
voltage for gate tensor pressure application at the start of the
drum after yarn splicing or at the end of spinning bobbin
winding.
The winding tension generally used is 8% to 12% of the
single-yarn strength.
Pre-clearer
It is possible to adjust the pre-clearer clearance by
changing the adjusting lever position according to the
scale on the tensor box.
The adjustment range is 0.4 to 1.8 mm; eight different
levels available, i.e., it can be adjusted in units of 0.2 mm.
Set it in accordance with the yarn count setting.

Bottom view of the pre-clearer

SPLICING
A high degree of yarn quality is impossible through knot, as the knot itself is
objectionable due to its physical dimension, appearance and problems during
downstream processes. The knots are responsible for 30 to 60% of stoppages
in weaving.
Splicing is the ultimate method to eliminate yarn faults and problems of
knots and piecing. It is universally acceptable and functionally reliable. This
is in spite of the fact that the tensile strength of the yarn with knot is superior
to that of yarn with splice. Splicing is a technique of joining two yarn ends
by intermingling the constituent fibres so that the joint is not significantly
different in appearance and mechanical properties with respect to the parent
yarn. The effectiveness of splicing is primarily dependent on the tensile
strength and physical appearance.
In these machine the splicing system are:-
Mach splicer
Hot Splicer
Water Splicer
Mach Splicer
The Mach Splicer overlaps the yarn ends from the package and bobbin sides, twists
them together using compressed air, and splices them together without a knot. The
Mach Splicer can join a broad range of natural and synthetic fibers of fine to coarse
count in the same time that it takes a mechanical knotter.

Mach Splicer
Splicing Operation
Yarn take-in Push the upper and lower yarn into
the splicer using the yarn guide levers, and then
clamp them there.
Cutting of the yarn ends the upper and lower yarn
cutters cut the ends of the upper and lower yarn.

Untwisting
The cut yarn ends are sucked into the untwisting pipe
and untwisted.
Splicing
The yarn guide lever is pushed in until it comes in contact
with the splice length control lever (Ln), pulling the yarn
end out of the untwisting pipe by the appropriate length.
While the yarn ends are out they are held by the yarn holding
lever, and a jet of compressed air from the splicing nozzle
tangles and twists the yarn ends together to complete the
splicing.
Hot Splicer
Hot Splicer is a device that uses hot compressed air for splicing.
Wool fabrics become soft when heated, making it easier to splice. By heating
up the twisting air, Hot Splicer is able to set optimum conditions for splicing.
While splicing worsted yarn with an Air Splicer, one needs to change settings,
parts and to perform complicated adjustments, depending on the type of yarn.
Hot Splicer requires no such adjustments, thus dramatically reducing the
maintenance time.
Mechanism of Hot Temperature Air Supply

Similar to the conventional Air Splicer, Hot Splicer also has untwisting
(black) and a splicing (red) air lines for compressed air. They are connected
to twisting pipe and splicing nozzle respectively.
The air heater, which is inserted into the 2nd valve, instantly heats up the
splicing air. The hot splicing air is supplied to the splicing nozzle, which
also has a built-in heater that maintains the temperature of nozzle as well as
the splicing air.
Water Splicer
The water splicer is a device that uses water to splice two yarn ends. By
mixing water particles with the twisting air, it is possible to splice yarn that
could not be spliced by an air splicer.
The splices that are created using the water splicer I have the following
characteristics.
It is possible to knot yarn types unsupported by the air splicer (two-ply
cotton yarn, and wet-spun linen, etc.)
The use of water provides a stronger and more stable splice part.
The use of water suppresses the hairiness of the splices.
Water Supply Mechanism
Like the conventional air splicer, the water splicer is equipped with an
untwisting air line and twisting air line. These are connected to the
untwisting nozzle and twisting device respectively.
The water supply line (blue line) is connected to the downstream side of the
twisting air line valve. Through the supply of a fixed quantity of water to
the twisting air line, the water that is on the line before the release action of
the twisting air valve will be ejected together with the compressed air when
the valve is released.
The water particles ejected during the splicing action are prevented from
dispersing into the surrounding area by a cover that covers the splice part.
The water that collects inside the cover is drained out of the machine via a
separately installed suction line.
Splicing Action
(1) Release of water valve:- The cam connected to
the yarn guide lever pushes the water valve and this
supplies water to the twisting air line.

(2) Setting the yarn in position .The yarn guide lever

pushes the top yarn and bottom yarn in the splicer
and then the yarn is clamped (by the clamp plate).

(3) Yarn end cut/Untwisting :-The top yarn and bottom

yarn ends are cut by the upper and lower cutter. The cut
yarn is sucked into the untwisting nozzle and untwisted
by an beater.
 (4) Splice:- The yarn guide lever is pushed in so that it reaches the position
of the Splice length control lever (Ln), and the yarn ends inside the
untwisting nozzle are pulled out to the appropriate length. After this, a lid
blocks the nozzle slit and at the same time the compressed air of the
twisting nozzle is ejected. This causes the yarn ends to intertwine with each
other and a twist is applied to complete the splice.
 Effect of Variables on the Properties of the Spliced yarn
The effect of various variables on the properties of the spliced yarn.
Effect of Fibre Properties and Blend
Effect of Yarn Fineness
Effect of Yarn Twist
Effect of Different Spinning Methods
Effect of Opening Pressure
Effect of Splicing Duration
Effect of Splicing Length
Effect of Splicing Chamber
Comparison of Dry and Wet Splicing
The comparative studies on dry and wet splicing with water showed that the
breaking load retention for wet spliced yarns are significantly greater than dry
spliced yarns. In fact, wet splicing is more effective for yarn made from long
staple fibres and for coarse yarn. This may be due to higher packing coefficient
resulting from wet splicing.
YARN FAULTS AND CLEARING:
It is still not possible to produce a yarn without faults for various reasons.
Stickiness of cotton can contribute to the formation of thick and thin places.
Fly liberation in Ringframe department is one of the major reasons for short
faults in the yarn because of the fly gets spun into the yarn. Hence it is not
possible to have fault free yarn from ring spinning, it is necessary to have
yarn monitoring system in the last production process of the spinning mill.
As physical principle for electronic yarn clearing the capacitive and the
optical principle have established. Both principles have their advantages in
specific applications.
 The quite extensive application of electronic yarn clearing has set new
quality standards with respect to the number of faults in spun yarns.
It is therefore necessary to evolve a method of yarn fault
classification before clearing the faults in winding. The most important
aspect is certainly the determination of the fault dimensions of cross-
sectional size and length. With such a cross-section and length
classification and by means of the correct choice of the class limits, the
characteristic dimensions of the various fault types can be taken into
consideration, then a classification system will result which is suitable
primarily for satisfying the requirements of yarn clearing and yet allows, to
quite a large extent, for a selection of the various types of faults.

N - NEPS
S- SHORT FAULTS
L-LONG FAULTS
CCP - COARSE COUNTS
CCM-FINE COUNTS

FIG: YARN CLEARING CONCEPT OF USTER QUANTUM CLEARER

 Yarn clearing

MAIN FUNCTIONS OF THE USTER QUANTUM CLEARER

The main functions are:
The elimination of disturbing thick and thin places
Foreign fibers
Short and long yarn count deviations
Detection of ring-spinning moir
Detection of deviations of the yarn irregularity (CV)
Detection of hairiness deviations
Monitoring of winder functions
Determination of quality characteristics
Triggering of alarms when preset alarm limits are exceeded
Generating reports
Principle of yarn clearing
1. During the winding process from bobbin to cone, the yarn is completely
monitored for yarn faults with an electronic device, the yarn clearer.
2. As soon as the yarn clearer detects a yarn fault, the yarn will be separated
by the cutter. The winding process is interrupted.
3. The yarn fault will be removed by the suction of the winding machine.
 4. Both ends, the upper yarn from the cone as well as the lower yarn from
the bobbin, are going to be combined again. The yarn joint is done by
splicing with a splicing device or knotting with a knotting device. The latter
is only used very rarely for special yarns. A good splice should not be
realized by the human eye. Present yarn clearer also monitor the quality of
the yarn joint.
5. The winding process continues up to the next fault or until there is no
yarn on the bobbin anymore.
Structure of the USTER QUANTUM CLEARER
The basic version of the USTER QUANTUM CLEARER can be
expanded by several features and options. Fig. shows the different
possibilities. The figure shows the dependencies from each other. Of
course, it is possible to combine other features of the USTER
QUANTUM CLEARER with each other depending on the quality
requirements.
 In the USTER QUANTUM CLEARER, the conversion is carried out
either with the sensor of the capacitive measuring principle or with the
sensor of the optical measuring principle. The sensor is part of the
intelligent measuring head iMK which also consists of the electronic
system to convert mass or diameter variations into an electric signal.

There are very high demands for both measuring principles regarding the
resolution and precision of the results. The sensor must be able to monitor a
yarn which runs with up to 120 km/h through the sensor and to detect even
very short faults. In order to achieve this, the yarn is measured every 2 mm.
The capacitive measuring principle
The electrical measuring condenser (1) forms the sensor for the capacitive
monitoring of the yarn mass. This is done by two parallel metal plates, the
electrodes. In the space in between (2), the two electrodes build an electrical
field when putting on an electrical alternating voltage (3). If a yarn (4) is
brought into this field, the capacity of the measuring condenser is changed.
From this change, an electrical signal, the yarn signal (5) is derived. The
change in the capacitance depends, besides of the mass of the yarn and of
the dielectric constant of the fiber material used, on the moisture content of
the yarn.
With the capacitive measuring principle, the yarn signal corresponds to the
yarn cross-section yarn mass, respectively, which is located in the measuring
field. Changes of the yarn mass cause a proportional change of the yarn
signal.
The optical measuring principle

The infrared light source (1) and the photocell (3) represent the sensor for
the optical monitoring of the yarn thickness. The infrared light is scattered
by a diffuser (2) in the light field and reaches the photocell (3). The
photocell emits a tension, which is proportional to the amount of light. If a
yarn (4) is brought in the light field, parts of the light will be absorbed by
the yarn. The amount of light, which hits the photocell, is smaller. From
this change, an electrical signal, the yarn signal (5) is derived.
 Influences on yarn measurement and yarn clearing
Influence Capacitive measuring Optical measuring
principle principle
Fiber material Most fiber materials can be Fiber material n be measured with both measuring
principles.
Yarns, which contain electrical
conductive fibers, cannot be processed.
Colored yarns No or only little influence Color differences within the bobbins
can lead to malfunctions
Fiber blends No or only little influence

Wax If the wax device is located below the yarn clearer, there is the tendency of a dirty
measuring field. The selection of a suitable wax can keep the contamination within
acceptable limits.
Contamination Usually, the measuring field cleans itself to a great extent by the yarn hairiness. In
certain limits, the yarn signal change, which is caused by the contamination, is
compensated electronically. When the limits of the compensation are reached, a
technical alarm for the respective iMK is triggered.
Atmospheric Normal variations in the humidity have no influence.
humidity
Yarn humidity Normal variation have no influence as long as the yarn structure is not changed.
WAXING PROCESS
Waxing is the process which is almost exclusively used in all automatic and
manual winding machines for yarns which are meant for knitting. This
helps to reduce the coefficient of friction of yarns created during knitting
process.
Extensive tests have shown that the coefficient of friction of waxed yarn is
not constant, but depends on the amount of wax on the yarn. It is proved
that both too little and too much wax cause increase in coefficient of
friction and thus detrioration in running efficiency on the knitting machine.
The recommended wax pick up for different material are given below:
cotton and its blends - wax take-up of 1.0 to 2.0 grams per kg of yarn
synthetics - wax take-up of 0.5 to 1.5 gram per kg of yarn
wool and its blends - wax take-up of 2.0 to 3.0 grams per kg
A further problem can arise during steaming, or any other treatment involving
the application of heat to a waxed package.
Low yarn tension will affect the wax pickup
Dimensions and form of wax rollers will affect the wax uniformity
 As it is clear and is important that, if the waxed particles are to carry out
their function, they must remain on the surface of the yarn. When the yarn
is subjected to heat however, the wax melts and penetrates to the inside of
the yarn body: it can then no longer work effectively.
When choosing the wax, it is essential to consider the type of yarn and
fibre, the temperature in the production area, etc., and the characteristics
indicated by the wax manufacturer
Winding process

The best winding speed is the speed which allows the highest level of
production possible for a given type of yarn and type of package, and with no
damage whatsoever to the yarn.(abrasion and breaks due to excessive tension)
Selection of Winding Speed
(1) Without Bal-Con
 (2) With bal-con

The graph above shows winding speed examples for different types of yarns
with spinning bobbins designed especially for high-speed winding. This is not
always the same, according to the type of spinning bobbin or winding
conditions.
Winding speed depends upon the following factors:-
Sloughing
Type and characteristics of bobbin
Take-up tube
Count
Type of yarn, (type of fiber, average strength and minimum strength)
Package taper
Final use of package
 For high-speed winding, it is essential to minimize sloughing. It is difficult
to remove sloughing completely with a yarn clearer and this can adversely
affect the quality of shipped packages.
Causes of Sloughing
The causes are listed below in order of frequency.
1) Number of coils (chase length) ............42%
2) Winding speed .................................................................................17%
3) Height of balloon breaker ...............................................................13%
4) Hardness of spinning bobbin ..........................................................12%
5) Relation between balloon breaker height and number of coils ......4.5%
6) Relation between winding speed and number of coils ...................4%
7) Others ............................................................................................7.5%
Type and characteristics of bobbin

The quality of the spinning bobbin greatly affects winder operation

(machine efficiency and work efficiency). In addition to full control over
the spinning process, which is of course important, the preferred shape for
spinning bobbins for use with this machine is shown below.

[Recommended bobbin dimensions]

d3 d2
d1 = d2 + 6 mm
d2 = 14 - 32 mm
a = 12 mm (minimum)
b = 10 mm (minimum)
L = 180 mm - 280 mm
D = 34 mm - 75 mm
H = 1.2 D
Take-up Tube

The accuracy and strength of the take-up tube is important for a high-speed
winding of 1,200 m/min or more. Insufficient accuracy and strength of the
take-up tube may cause drop-out of the package from the holder during
winding. An increase in the winding speed also increases the risk.

.................................................................................3 15 to 5 57
L .................................................................................170 to 178 (1) mm
t ..................................................................................2 mm or more
Fluctuation at smaller diameter side at part A ............0.2 mm or less
Resistance to the force from F ...................................20 kg or more
D and d eccentricity .............................................None
d and D diameter variation ................................... 0.2 mm or less
 Take-up tubes with a V or U-shaped cutout, as shown in the photos below,
can easily be deformed when the package brake is activated, possibly
causing the package to step wind or come off, and therefore their use is not
recommended.

V-shaped U-shaped
Ribbon Winding
Ribbon Winding:-A ribbon winding is a rope-like pattern in which the
wound yarn is superimposed in approximately the same position.
This cannot be avoided if a conventional drum is used.
As shown by a in figure, the yarn is wound with a displacement. This
displacement is almost zero for an approximately 200mm diameter package
with a 2W drum, and for an approximately 250mm diameter package with a
2.5W drum, and a single-wind large ribbon winding is produced when the
drum diameter is 100 mm.
For the following reasons, this single-wind ribbon winding presents the
most difficult problem with high-speed unwinding.
(1) As the diameter of the package is considerable, the unwinding yarn
balloon does not readily expand.
(2) The cross-point between yarns is limited to one point on the ribbon
winding, and the force holding the yarn in the package surface layer is
minimal.
Drum Wind Control (jumping system)
Control Mechanism:- 2-winds, 1.5-winds, and single-wind winding on the
package surface is liable to result in a ribbon winding with both 2W or
2.5W winding.
The drum wind controller is therefore used to form a package suitable for
high-speed unwinding by switching the number of winds at before and after
this particular package diameter.
when the drum wind controller is not operating the yarn is introduced into
the outer groove (i.e. the groove with the 3W winding angle (lead angle)).
When the drum wind controller operates the yarn is introduced into the
inner groove (i.e. the groove with the 2W winding angle (lead angle)).

Drum wind
controller
 Controlling the Number of Winds The drum wind controller controls the
number of drums in order to prevent the number of winds on the package
surface from reaching 2 winds, 1.5 winds, or single wind. The VOS screen
automatically sets the timing of activating the control of the drum wind
controller.
The wound package is shown in the figure.
 Poor Winding Shape
Cause Action
[1] Bulge The internal compression is increased as (1) Lower the number
winding the winding diameter is increased due to of drum
the increase in the contact pressure of wind (from 2W to
the package on the drum or to the 1.5W)
increased density of the yarn. Thus, the (2) Tension release is
internal yarn layers buckle. This occurs necessary for coarse
with coarse yarn and two-ply yarn. yarn or bulky yarn.
(1) Winding angle is too large. (3) To reduce contact
(2) Winding tension is excessive. pressure, a pressure
(3) Contact pressure is too high. reducer is necessary.
[2] Wrinkles This is caused by short traverse at the (1) Improve the
start of winding, reduced tension by tension and contact
slipping, and also by the bulge winding. pressure.
(1) Inadequate tension and contact (2) Remove defective
pressure. take-up tubes.
(2) Deflection of take-up tube center. (3) Correct the small
(3) Poor adjustment of contact surfaces diameter driving of
of take-up tube and drum. take-up tubes for
(4) Excessive application of increase. paired drums.
 Cause Action
[3] Scramble (1) Drum does not stop at yarn (1) Replace the yarn
breakage. clearer. Check MS2.
(2) Joining motions repeats several (2) Check the joining
times. motion and yarn path.
(3) Suction mouth comes in contact Also check the splicer.
with package. (3) Adjust the suction
(4) Contact pressure is too low. mouth stopper.
(5) Ribbon comes off.
[4] Stitch The yarn is dropped off the edge of 1) Set the tension
package. properly.
(1) Inadequate tension or variation of (8 to 12% of single
tension. yarn strength)
(2) Flaw near the drum nose. (2) Correct the flaw on
(3) Improper rotation of cradle the drum.
bearing center. (3) Replace the cradle
(4) Loose cradle. bearing.
(5) Improper position of drum to (4) Correct the loose
cone holder. cradle.
(6) By ribbon winding. (5) Adjust the cradle.
(7) By sloughing. (7) Increase the
(8) By low humidity (hemp, acrylic) humidity to 60%
or more.
 Cause Action
[5] End missing At the winding end of spinning 1. Increase the humidity
bobbin or at yarn breakage, yarn end (60% or more).
is wound on the either end of the take- 2. Remove the cause for
up tube or wound into the package sloughing.
layer. 3. Improve the spinning
(1) Improper gap between the drum process.
cover and the package. 4. Improve the spinning
(2) Excessive sloughing. bobbin building
(3) Excessive surface cut of spinning (spinning process) or
bobbin. lower the winding speed.
(4) Winding speed not suited to
spinning bobbin building.
[6] Ribbon This is most likely to occur when the (1) Change the
winding ratio of the drum diameter and disturbance setting.
package diameter is an integer. (2) Lower the contact
With rotary traverse type of winder, it pressure.
is not possible to completely prevent (3) Replace the bearing
ribbon winding, but dispersing is of cradle if the rotation is
possible. heavy.
(1) Improper setting of disturbance.
(2) Excessive contact pressure.
(3) Improper rotation of cradle.
 Cause
[7]Stepped (1) Flaw on drum.
winding (2) Flaw on drum cover.
(3) Low tension.
(4) Disengaged yarn from the
yarn path after machine cleaning.
[8] (1) Improper guiding of yarn to
Pattern winding the tensor.
(2) Foreign substance on tensor.
(3) Excessive variation in
unwinding tension due to
improper forming of spinning
bobbin.
(4) Low increase.
(5) Bal-Con adjustment problem.
(6) Low tension.
Action
(1) (2)Check the flaw
and repair by sanding.
(3) Increase the tension.
(4) Be careful not to
blow the yarn when
cleaning with air.
1) Check and correct
any flaw on yarn guide.
(2) Clean the tensor.
(3) Check and improve
the spinning bobbin
building.
4) Improve the increase.
(5) Adjust the Bal-Con.
(6) Increase the tension.
 Cause Action
[9] Saddle back (1) Over tension. (1) Lower the tension.
package (2) Low contact pressure. (2) Increase the contact
(3) Low increase. pressure.
(3) Improve the increase.

[10] Swelled (1) No tension is applied. Poor return of tensor

package Improper guiding of yarn to tensor. cutter.
Foreign substance staying on tensor. Clean tensor.
(2) By ribbon winding.
Q UERIES..?