(Woodhead Publishing India in Textiles) Bhattacharya, Someshwar S. - Shaikh, Tasnim N - Engineering Techniques of Ring Spinning-Woodhead Publishing India PVT LTD (2016)

Engineering techniques of ring spinning
Engineering techniques of
ring spinning
Dr. (Mrs) Tasnim N. Shaikh

and
Dr. Someshwar S. Bhattacharya
WOODHEAD PUBLISHING INDIA PVT LTD

New Delhi
CRC Press Woodhead Publishing India Pvt. Ltd.
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Version Date: 20151014
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Contents
Preface ix
1. Introduction to ring spinning technique 1

1.1 Introduction 1
1.2 Significance of ring spinning technique 1
1.3 References 2
2. Basic features of ring spinning machine 3

2.1 Introduction 3
2.2 Basic objectives 3
2.3 Working of ring frame 4
2.4 Skeleton structure of machine 6
2.5 References 8
3. Design features of creel and drafting system variables 9

3.1 Introduction 9
3.2 The creel 9
3.3 The drafting system 14
3.4 References 48
4. Twisting mechanism 49
4.1 Introduction 49
4.2 Twist mechanism in ring spinning 49
4.3 Working elements of twisting mechanism 50
4.4 Twist 88
4.5 References 95
vi Engineering techniques of ring spinning
5. Balloon theory 97
5.1 Introduction 97
5.2 Vibrating string theory in brief 97
5.3 Application of vibrating string theory to ring spinning 99
balloon
5.4 Basic conditions for stable spinning 101
5.5 Spinning parameters influencing spinning balloon height 101
5.6 References 103
6. Winding mechanism 104

6.1 Introduction 104
6.2 Spindle 104
6.3 Cop winding 114
6.4 References 118
7. Builder mechanism 119

7.2 Ring frame bobbin 119
7.3 Structure of cop 120
7.4 Cop building pattern 120
7.5 Builder mechanism 121
7.6 References 142
8. Doffing 143
8.2 Doffing 143
8.3 Types of doffing 144
8.4 Basic working elements of auto doffing 145
8.5 Doffing preparation 147
8.6 Doffing cycle 147
8.7 References 149
vii
Contents
9. Spinning geometry 150

9.2 Spinning geometry 150
9.3 Important factors influencing spinning geometry 151
9.4 References 162
10. Yarn tension theory 163

10.2 Yarn tension involved in ring spinning 163
10.3 Need of yarn tension in different zones of ring spinning 164
10.4 Various forces acting on the traveller 165
10.5 Mathematical expression for yarn tension 166
10.6 References 169
11. Parameters influencing yarn tension during spinning 171

11.2 Parameters influencing yarn tension during spinning 171
11.3 References 178
12. Means of controlling spinning tension variations 179

12.2 Means of controlling spinning tension variations 179
12.3 Yarn tension contributors 180
12.4 Means for controlling balloon height 182
12.5 Means for controlling spindle speed 183
12.6 References 188
13. Optimization of ring spinning parameters 189

13.2 Optimization of ring spinning parameters 189
13.3 References 201
viii Engineering techniques of ring spinning
14. Material handling 202

14.2 Conventional mode 202
14.3 The need for automation 203
14.4 Automatic material handling 204
14.5 References 205
15. Measures of process control 206

15.2 Conventional approach 206
15.3 Modern approach 207
15.4 References 210
Index 211
Preface
Several new techniques of spinning have been arrived in the commercial

market but yet not able to create big threat to the most versatile ring spinning
technique for staple fibers. This is mainly attributed to superior yarn
properties, capability of spinning all types of fibers with very wide range
of yarn counts 6s Ne to 250s Ne as on today. Continuing efforts have been
made by the researchers and manufacturers to improve the quality as well as
productivity further to stay a long in a competitive market. Critical analysis of
various changes in the engineering design of machine variables and scientific
approach taken to optimize process variables is very vital. This has been the
main focus while preparing this book.
The authors are in teaching professions for so many years and dealing
with the subject ‘Ring Spinning’. They felt deeply that there is a need to have
a textbook with a compact source of knowledge on a wider span topic of
ring spinning. There are so many excellent books available in this field, but
information is scattered. Students need to struggle for getting well-compiled
information from one origin. Therefore the authors have thought to prepare
a book by keeping textile undergraduate and postgraduate students in mind.
The book can inculcate the basic concept of ring spinning and various
technological advances step by step. It is expected that the content of this
book will be useful to all academic institutes engaged in teaching textiles and
professionals working in textile industries.
The book is divided into fifteen chapters. The initial chapters describe
the fundamental concept of a ring spinning system and the main machine
parts with necessary diagrams. The objective behind is to make ring frame
and its functions easily understandable to the reader. The next set of chapters
describes precisely sequential operational systems from feed zone to the
bobbin buildup. The importance of the machine parts related to technical
parameters and the quality of the final product are well incorporated. To
understand the ring frame thoroughly, some of the technical parameters need
x Engineering techniques of ring spinning
to be studied thoroughly, like balloon theory, spinning geometry, yarn tension

theory, parameters influencing the yarn tension and also means for its control
etc. They are well incorporated in a proper sequence and the sincere efforts are
given to discuss thoroughly and technically.
This book is the fruit of the joint efforts of the authors. We would like to
acknowledge them who helped us for supplying the technical and mechanical
parameters. We would also like to convey our thanks to all who helped us
directly or indirectly.
Vadodara, Gujarat Dr. T. N. Shaikh
November 2014 Dr. S. S. Bhattacharya
1
Introduction to ring spinning technique
Abstract: Ring frame is the last machine in the production chain of fiber-to-yarn
conversion process. It is designed to convert roving to final state yarn by drafting
and twisting. The product yarn is wound in a peculiar pattern on a bobbin,
suitable for the forthcoming processes in the sequence. Ring frame holds a major
share in defining cost and quality of a spinning mill product. Thus spinning mill
economy and performance keys lies in the hands of ring frame. So, many a times
in narrower sense, ring spinning term is used only to the ring frame.
Key words: Ring frame, versatile, drafting, twisting, economy
1.1 Introduction
Spinning refers the conversion of staple fibers to continuous length twisted
strand of fibers that is yarn, of desired size. According to the structural
characteristics, yarn is the continuous strand of straight, parallel and randomly
arranged fibers twisted together. Thus conversion process of fibers to yarn
includes number of steps. The entire sequence of process is known as spinning.
Since ring and traveller are used as a media for inserting final turns of twist to
the strand, the set is recognized as ring spinning.
1.2 Significance of ring spinning technique

Ring spinning process is broadly classified as short staple spinning and long
staple spinning purely on the basis of length measure of the fibers spun together.
Ring spinning technique has found superiority over the other processes used
in commercial market in short staple spinning, especially cotton spinning.
The dominating position of the ring spinning machine in the commercial
market is mainly attributed to clear recognition of its inherent features for
wide range of products offered by market players. This favourable stand given
to this oldest technology is mainly due to its considerable advantages over the
unconventional spinning processes, in terms of quality and versatility. The
system versatility lies in terms of type of material and yarn. As mentioned
above, it can comfortably deals with short staple cotton to long staple manmade
2 Engineering techniques of ring spinning
fibers or even their blends. It is capable of spinning various categories of yarns

to suit different end uses, starting from soft (knitted yarn) to hard twisted
(crepe yarn), very coarse yarn (6s Ne) to superfine yarn (250s Ne), custom
yarn to functional yarns, carded yarn and combed yarn, etc.
Conversely to its versatility, economy and ease of operating point of
view, it has faced many difficulties in making a substantial breakthrough.
Longer machine chain involved in the production course and limitations in
increasing production rate are the two major hurdles in this labour-intensive
spinning mill. Continuous efforts are put forward by machine manufacturers
to overcome these limitations. Many engineering techniques have been
incorporated on their latest models in this course. However, this exercise has
made capital investment for ring frame also higher. But increased production
rate and number of working units per machine along with reduced involvement
of labour compliment has shorten the payback time and made the system
economical on a longer run.
Ring frame is the last machine in the production sequence of ring spinning.
It is designed to convert roving to final state yarn by drafting and twisting.
Apart from this, it gives a major contribution in defining cost and quality of a
spinning mill product. Thus, spinning mill economy and performance mainly
lies in the hands of ring frame. So, many a times in narrower sense, term
‘spinning’ applies only to the ring frame.
1.3 References
1. De Barr and Catling H. (1965). ‘Manual of Cotton Spinning: The Principles and
Theory of Ring Spinning,’ Manchester, The Textile Institute.
2. Gilbert R. Merrill (1959). ‘Cotton Ring Spinning’, Mass, Gilbert R. Merrill, Library
of Congress catalogue card number: 59-10906.
3. W. Klein (1987). ‘The Manual of Textile technology: Vol. I – The Technology of Short
Staple Spinning’, Manchester, The Textile Institute.
2
Basic features of ring spinning machine
Abstract: Ring spinning is a versatile technique for spinning wide varieties of

yarns for different end-use purposes. However, feed material characteristics as
well as end product characteristics vary in this course, but steps follow during
conversion mechanism remain same irrespective of them. That’s why the basic
objectives and set up of ring frame remains identical since decades, although
undergone many engineering and technological changes for high speed production
of further broaden range of yarns. Added feature of auto doffing is incorporated
in the basic infrastructure of the modern machines.
Key words: Roving, creel, drafting, twisting, spindle, winding, auto doffing, ring
rail
2.1 Introduction
Ring spinning process is designed to convert continuous strand of group of
fibers known as roving to yarn. Roving holds the same technical definition
of ring spun yarn, but they differ in terms of their fineness (size) and amount
of twist employed. The roving stands on coarser side (0.6 s Ne to 2.5s Ne)
with quite a low amount of twist (0.7 to 1.2 TM). These values purely depend
upon the type of fibers in process and type of yarn to be spun. However, steps
follow during conversion mechanism remain same irrespective of variations
in feed material characteristics or yarn characteristics desire. Thus the basic
objectives and set up of ring frame remains identical for the very wide range
of yarns.
2.2 Basic objectives

i. Draw the fed roving to desired yarn fineness in the drafting system
ii. Impart enough strength to the drafted strand composed off parallel
fibers, for sustaining the forthcoming stresses by twisting it. Amount
of twist apply depends mainly on end-use requirements, and
iii. Wind up the product yarn compactly in a suitable pattern on a ring
frame bobbin (cop) for ease of storage, transport and downstream
processing.
2.3 Working of ring frame

Based on the objectives of ring spinning, the working of entire machine can
be subdivided into three main sections (Fig. 2.1):
i. Creel section or feed section
ii. Drafting section,
iii. Spinning and winding section.
Figure 2.1 Working of ring frame
2.3.1 Creel section

It is composed of number of holders supported on the basic frame. The roving
bobbins are supported vertically on holders mounted on the creel. Guide
bars facilitate nose unwinding of the rovings and fed into the next section –
drafting. Thereby this section is also referred as feed section.
Basic features of ring spinning machine 5
2.3.2 Drafting section

Its function is to attenuate fed roving to final desired yarn fineness. The two
zone, 3 over 3, top arm drafting system is normally employed for the purpose.
The drafting system is mounted on the roller stand, the support frame with
roller bearing housing. It is kept inclined at an angle (ranges from 30° to 60°)
with basic frame (roller beam). This arrangement permits twist to flow right
up to the nip of the front roller.
2.3.3 Spinning and winding section

The drafted ribbon, on emerging the front roller nip, is diverted to the spinning
plane by a lappet guide. It is a smooth surface self-threading, rounded guide
eye. It is off set horizontally as well as vertically from the front roller nip for
the smooth twist flow. The guide eye is kept in perfect alignment with the
spindle axis for the formation of symmetrical balloon at the point of spinning
or twisting. This is the basic condition for spinning stability and achieved by
keeping control on spinning tension variations.
The drafted ribbon of fibers receives the necessary turns of twist on
emerging out of the front drafting roller nip. This twist imparts necessary
strength to finer and weaker drafted ribbon to sustain forthcoming stresses of
spinning. Twisting turns are generated by the traveller. The element moves on
a guide rail around the spindle, the so-called ring. All the rings are fitted on the
long continuous hollow channelled metallic plate, viz., ring rail. The traveler
has no drive of its own; it is dragged with spindle via the yarn attached to it. In
the process each rotation of the traveller on the spinning ring produces a turn
of twist in the yarn. Traveller also acts as a yarn guide for winding yarn on the
bobbin.
Spindle is a shaft for ring cop. It rotates at high speed from the main
drive. The rotation of spindle also drives the bobbin mounted firmly on it, by
the same speed. However, the rotation of the traveller lags behind that of the
spindle and thereby helps in bobbin lead winding. Difference in the speed of
spindle and traveller defines the winding speed. Tapered plastic (earlier paper)
tubes with the inner diameter compatible with spindle profile have been used.
Winding of the yarn is normally carried out as per weft wind pattern with the
help of movable ring rail. Ring rail is provided with continuous traversing.
The length of the traverse is always shorter than the full winding height (lift)
of the tube. The rail has also given slight upward shift after winding each
layer to shift starting winding point of the next layer in sequence upward. The
bobbin so build up has tapered shape, less prone to slough off during handling,
transportation and unwinding.
2.4 Skeleton structure of machine

Ring frame has productive units (spindles) arranged lengthwise and driving
elements along with auxiliaries accommodated widthwise. Number of
productive units is highest at the last stage of production process, 440 spindles
(conventional) to 1864 spindles (modern). Thus, the broader lengthwise
outline compared to narrower widthwise span of ring frame machine forms
a rectangular block. It is divided into three zones for the conventional slow
speed frame and four zones for the modern high speed frame (Fig. 2.2). The
fourth one is the doffing end apart from the three basic ends. The basic ends
are head end, production end and tail end. The major length is occupied by the
manufacturing section, located at the mid of the frame.
Figure 2.2 Lengthwise bifurcation of basic frame work of ring
2.4.1 Manufacturing end

The skeleton of long, manufacturing mid-section of the machine has a mirror
replicas on both the widthwise end points of the ring frame. These sides
are referred as: right hand side (R.H.S.) and left hand side (L.H.S.). They
form replica of each other in terms of their machine design and functioning
(Fig. 2.3). So, ring frame is referred as double-sided machine. Each side
consists primarily of continuous longitudinal solid and robust C-shape plate,
known as ‘spindle rail’ and solid rectangular block, known as ‘roller beam’
along its entire length. They are attached together at many junctions by cross
beams. They strengthen the skeleton structure of the frame. The cross beams
for roller beams also serve as supports for the bobbin creel. Holes are bored
on the spindle rail at equal distance to plumb the spindles. Roller stands for
drafting system are mounted in the holes bored on the roller beam at equal
spacing as per the gauge length. Each center frame stands on two feet which
Basic features of ring spinning machine 7
can be adjusted in height by screws, which facilitates leveling of the machine

for vibration free running. Hence machine parts involved in this section are
participating in production process, this sector often referred as production
end.
Figure 2.3 Widthwise bifurcation of skeleton structure of ring
2.4.2 Head end

It represents small vertical rectangular block on the left hand side of
manufacturing end of frame (Fig. 2.2). Entire drive gear set up for the
machine is accommodated in this block, starting from the motor. Since
continuously rotating gears, cams, etc., are the main elements of this section,
it is always furnished with lubricating system. It may be operating on manual
(conventional) or auto (modern) mode.
2.4.3 Tail end

The right hand side block to the production end is referred as tail end or off
end of the machine. It incorporates auxiliaries of driving mechanism and
assisting systems of the production mechanism, like the drive transmission

elements, electrical and electronic components, brake system and the thread
extraction filter, respectively. Head end and tail ends are located at end points
of the production end, together often referred as end stocks.
2.4.4 Doffing end

This is not a mandatory section of the basic frame work. It is a compulsory
feature of the modern machines equipped with auto doffing attachment. Such
ring frames have automated doffing unit, including the doffer. It is located next
to the tail end. The total machine width varies between approx. 800 and 1000
mm (up to 1400 mm with doffer arm extended). The length of the machine can
be up to 50 m and more, with up to 1600 spindles per machine. Spindle gauge
is usually between 70 mm and 90 mm. Spindle gauge refers center to center
distance of two consecutive spindles on the spindle rail.
2.5 References
2. Rieter, Spun Yarn Systems, http://www.rieter.com/cz/rikipedia/articles/ring-spinning.
[Accessed 10 June 2014].
3
Design features of creel and drafting
system variables
Abstract: The entire ring spinning machine structure can be bifurcated into
three basic sections according to their role in production process. These divisions
are true for all categories, viz., (i) creel section, (ii) drafting section, (iii) spinning
section, and (iv) winding and bobbin building section. The contribution of each
section in the production course is well defined. The machine components are
accordingly engineered to meet these objectives. No doubt in order to maintain
pace with high speed production techniques, they have undergone many changes
in terms of their metallurgy, shape, dimension, etc. Since lot many areas and
their respective details are involved under these heading. So, the content is
divided into four chapters. The first part deals with creel section and drafting
section only. Their machine variables and respective changes in their engineering
design with advanced technology are briefly summarized in this chapter.
Key words: Creel, regular creel, skewer, open creel, pivot holder, sprung arms,
umbrella creel, drafting system, steel rollers, soft rollers, twine roller, loose boss
roller, roller bearing, staff length, fiber guidance devices, double apron, short
apron, long apron, roller nip, spacer, distance clip, scavenger roller, clearer roller,
pneumafil, bonda waste, soft waste, white waste, inverter, transducer, draft
constant, draft change wheel, high draft ratio, high draft speed, spinning triangle,
angle of wrap, roller stand angle
3.1 Introduction
Previous chapter has focused on the basic structure and aims of ring spinning.
Accordingly, the entire ring spinning is divided into three basic sections for all
categories: (i) creel section, (ii) drafting section, and (iii) spinning and winding
section. The contribution of each section in the production course is well
defined. The machine components are accordingly engineered to meet these
objectives. No doubt in order to maintain pace with high-speed production
techniques, they have undergone many changes in terms of their metallurgy,
shape, dimension, etc. They are briefly summarized in this chapter.
3.2 The creel

Creel is the machine part designed for the supply of raw material, here it is a
roving. Roving is packed in the form of tapered bobbin of the weight ranging
between 800 gm (conventional) to 3–3.5 kg (modern) at speed frame. So, the

design set up of creel involves arrangement for mounting this bobbin and
free withdrawal of roving at desired feed rate. Supply package is vertically
suspended at the creel irrespective of type of ring frame. Package is driven
negatively by the pull of roving, caused by back drafting roller. Owing to
negative mode of withdrawal, design of creel becomes utmost important to
meet the basic objectives of the creel.
3.2.1 Basic objectives of the creel

The creel must permit
i. Trouble free take off of the roving from the heavy supply package.
Otherwise liable to result in false drafts or roving stretch. The situation
becomes more critical with heavy weight bigger size package.
Rotation of such a heavy package by the pull of soft and weak roving,
likely to result in end breaks due to higher roving stretch involved.
Here false draft or roving stretch refers the unwanted extension
caused in fed length of roving due to unwinding tension.
ii. Ease of creeling or replacement of the empty bobbin with full bobbin.
iii. Availability of enough lighting and space for maintenance and
cleaning.
3.2.2 Types of creel

There are basically two types of creels in use on commercial ring frames:
i. Regular creel
ii. Open creel: Overhead creel or umbrella creel
Regular creel
This creel is made up of three wooden boards, top creel board, middle creel
board and bottom creel board (Fig. 3.1). They form two compartments
to accommodate the required number of bobbins. Bobbins are mounted in
zigzag fashion in two raw per compartment to get enough spacing for ease of
donning and retaining alignment with the feed line. The boards are supported
on cross beams, capable of making vertical adjustments on vertical support
bars provided at regular interval. The number of cross beams varies depending
on the length of production end. The support bars are fitted on roller beams.
The distance between the creel boards is adjusted to suit the size of supply
package. Hence all the packages are mounted on wooden spindle known as
skewer. So, setting of the boards is done in such a way that the skewer projects
Design features of creel and drafting system variables 11
well into the holes in the upper one but does not project above its upper
surface. Holes have been punched in zigzag pattern as per spindle gauge and
covered well with porcelain guides on creel boards. Porcelain guides reduces
friction between skewer and board hole. Top and bottom boards have such an
arrangement only on one working side, but the middle one provided on both
the sides. Skewers fit into these guides, to work with negligible abrasion.
Figure 3.1 Regular creel
Skewer: It is a long hard wood spindle, tapered at both the ends (Fig. 3.2).
Its working cylindrical height is known as barrel. The barrel diameter of the
skewer (dB) is always smaller than the inner diameter of the supply bobbin
(dP), to avoid undue friction between them, at the point of roving withdrawal.
The barrel is rounded at bottom to form the base, to support the bobbin base
and not allow it to slide down further.
The roving bobbin is rotated by the pull of the roving. Owing to bigger
inner diameter of the bobbin, it rotates freely around the skewer, without
making any frictional contact. Strands of roving are drawn from the bobbin
to the roving guide of the drafting system. The difference in the path length
for top and bottom compartments of the creel adds to the unwinding tension
variations. Thereby smooth steel guide rod is provided, outside and well
above middle guide board. All the rovings from the upper compartment are
lead over this rod before entering to the roving guides. This can minimize the
tension variations due to difference in their path lengths.
Figure 3.2 Regular creel skewer and roving bobbin
Limitations of regular creel: The regular creel is simple and robust in

design but suffering from many limitations. They are:
i. It does not allow working with large size supply package and high
delivery speeds. Negative withdrawal of roving adds to the roving
stretch. Incorrect draft or even thread break can occur. The situation
becomes more crucial with full heavy package, high speed and
weaker roving. These limit the size of the roving package and thereby
increase donning frequency on ring frame and doffing on flyer frame,
adversely affect the efficiency of both the machines.
ii. Creeling time is high due to use of skewer. Mending of the ends and
replacement of bobbins is rendered difficult for rear raw bobbins.
iii. Storage and maintenance cost gets added owing to the use of skewer,
creel boards and porcelain guides.
iv. The creel boards cover up the area above the roller beam well thereby
do not permit dirt and lint from dropping down. However presence
of these boards above the roller beam interferes air circulation and
light path, thereby cleaning and maintenance becomes difficult. It
demands extra lighting for better working, adds to yarn cost.
v. The weight borne by the roller beam exceeds due to additional weight
of boards, support beams and skewers.
vi. If a skewer is dropped due to careless handling, liable to burr up its

bottom end. This produces too great a bearing surface in the step
bearing of the creel and may develop extra tension to cause the roving
to break repeatedly. This demands additional storage for spare skewer
to replace the damaged one in right time.
Abide by all these limitations, although simple it has found success only
on conventional slow speed ring frames.
Open creel
This creel uses bobbin overhead suspension pivots instead of bobbin holders;
skewer, so often referred as overhead creel. They are bolted onto several
support rails (triangular channel) arranged one behind the other along the
entire length of the machine (Fig. 3.3). There is one pivot for each spindle.
Hence quite smaller in size and suspended overhead onto support rail, offers
much higher free open space. Thereby put under the name of open creel. This
abundant open space provides enough room for the creeling and air circulation
in the cleaning process.
Figure 3.3 Bobbin overhead suspension pivot
The suspension pivot is composed of hollow aluminum cylindrical

housing. Two aluminum crossing bobbin retainer tongues, having bird’s wing
shape, are provided. They are capable of springing in and out just like birds
wind, so often referred as sprung arm in many place. They are resting on the
limiting pin, inside the hollow tube under their own weight in the absence of
external force. When the sprung arms swing out, increases resultant diameter
(D) of the holder than the inner diameter of the roving bobbin tube. Thus
holds the roving bobbin in position. If bobbin along with driver ring is pushed
up, the top ends of the sprung arms resting on the ring moves right up with
them. Their bottom ends are inserted in the pivot housing, restricted by the
cylinder dimension. So, in order to follow upward push, retainer for the
bobbin swings in. The retraction of arms reduces its resultant diameter (d)
smaller than bobbin tube diameter. This helps in mounting of full bobbin or
withdrawal of empty bobbin tube from the holder.
Fiber washer is provided to minimize friction between base of arms and
housing during their spring in-out moves. The pivots cylindrical housing is
mounted on ball bearings, provides frictionless free rotation to it and thereby
the roving bobbin, suspended on it. This can help in minimizing roving
stretch. Tension finger is a steel wire loop integrated in the bearing unit on
suspension pivots and set closer to full bobbin. It acts as a light brake loop,
occasionally presses gently against the bobbin. This prevents over-rotation of
the bobbin, by not allowing it to rotate too fast. Thus acts like a brake for the
roving bobbin, so often said as brake loop.
Nowadays suspension pivots are made up of fiber material to reduce
weight and increase serviceability. Even reversal springs are incorporated for
driver rings for assured reversal. Umbrella cap provided at the top end of the
cylindrical housing prevents dropping of dirt and fly on the bearing. Otherwise
they can chalk up the bearing and obstruct its frictionless working. Due to use
of umbrella cap, this creel is also known as umbrella creel. This creel has
found space on all modern machines by overcoming all the limitations of
regular creel. As it offers following advantages:
i. It occupies less space in terms of width, offers enough lighting and
ease of maintenance and cleaning.
ii. Very large roving bobbins are used without having the fear of false
draft, due to free rotation of heavy bobbin on bearing.
iii. Having longer life and almost nil fear of getting damage.
iv. Less number of parts involved in the structure, provides considerable
reduction in storage cost.
v. Light-weight fiber material is used in the structure of suspension
pivots along with less number of accessories (support channel only).
So, less weight is born by roller beam.
3.3 The drafting system

Drafting is the generic name given to the process used for reducing the bulk
and weight per unit length of the semi-processed textile materials like roving
and sliver, and simultaneously parallelizing its fibrous components, as it

passes through various machines used in yarn formation.
Three over three, double-apron top arm drafting system (Fig. 3.4) is used
exclusively on modern short staple ring spinning machines. As the name
suggests, it consists of three pairs of drafting rollers. Bottom fluted steel rollers
are supported in housing provided on the roller stand. Whereas, top synthetic
rubber coated rollers are positioned above them. Top rollers are housed in
the bearing housing carried by an arm, known as top arm. Such suspended
top rollers are pressed against bottom rollers by lowering a pressure arm (top
arm). Similarly they are relieved from the load by lifting the pressure arm.
The loading media can be a spring (conventional) or compressed air (modern)
pressure for the top arm.
Figure 3.4 3 Over 3, Double-apron top arm drafting system
Three pairs of rollers make two drafting zones (Fig. 3.4). The back zone
of the system is known as break drafting zone. The amount of draft employed
is always less but enough to remove the roving twist. This is required in order
to straighten fibers in the roving and gets them ready for receiving major
draft. In order to obtain optimum results, the break draft zone must be set in
such a way that the roving is under tension in this zone, but only sufficiently
for no real drafting to occur. This is achieved with break draft nip distances
of 60–80 mm and break draft settings of 1.03 to about 1.3. Unfortunately,
generally applicable optimum settings for every case cannot be stated, since
they depend heavily on fiber material, roving count and roving twist.
The front drafting zone also known as major/main drafting zone, as

roving thickness is attenuated to desired yarn fineness in this zone only. Since
amount of draft involved in this zone is high, fiber bundle with only few fibers
has to be transported in the main drafting zone. So, positive fiber control and
guidance is must. Thereby the main drafting zone is provided with a guide
unit consisting of rotating bottom and top aprons.
The drafting mechanism holds the most important position in the
conversion process of roving to the yarn on the Ring spinning machine. It
primarily influences the major yarn properties, viz., uniformity and tenacity,
as well as economy of the yarns. The economy of the yarn is influenced
directly via ends down frequency and indirectly via degree of draft. If
higher drafts can be set in the drafting system, this enables coarser roving
to be supplied. However, coarser roving signify in turn higher production
performance of the roving frame and thus savings on roving spindles, i.e.
a reduction in machines (roving frames), space, personnel, etc. However, if
the draft is increased too much, this can result in a reduction in yarn quality.
Thus selection of correct amount of draft has found prime importance in ring
spinning. Upper limits of drafting in mill operations are well defined with
respect to modern high draft, 3/3 pneumatic top arm drafting system with
proper fiber guidance. They are as follows:
• carded cotton yarn up to 40
• carded yarn blends up to 50
• combed cotton and blended yarns
• medium counts up to 60
• fine counts up to 70
• superfine counts up to 120
• manmade fibers up to 45 (–50).
Drafting system thus includes variables: ‘bottom drafting rolls, top
drafting rolls, aprons, top arm, roller cleaning system and roller stand’.
3.3.1 Bottom rollers

Bottom rollers are made of steel, often case hardened. Case hardening is done
by heating the roller. The heat should be penetrated only to a depth of 0.5–1.0
mm. So that only case is hardens but not the entire roller. They are driven
positively from main drive. The longer length of roller is split into sections
to impart ease of maintenance and replacement. Whenever required the
section is replaced rather than entire roller. This makes not only work easy but
also economical. The section length varies from 432 mm to 610 mm to suit
gauge of the frame. The length of the section is also referred as staff length.
Number of such individual sections are joined together in order to form long
continuous roller to suit the machine width. The roller sections fitted together
either by square joint as per older system or by screw joint as per new system.
In screw joint the screw threads engraved are opposite to that of the rotation
of roller, to prevent opening of the roller joint.
Each individual section is made from a length of round steel bar. The
portions of the roller, which are not used for drafting, are turned down to
around 2.5–3.0 mm smaller in diameter than the working section. This helps
in reducing revolving mass and thereby savings in power cost. The working
width of the roller is known as boss. It is provided with flutes for ensuring grip
on moving fiber flux. The density of flutes varies in inverse relation to fiber
flux passing through; less for back roller and higher for front roller. Bottom
rollers are classified into three categories based on flutes type:
i. Parallel flutes roller,
ii. Helical flutes roller and
iii. Knurled roller (Fig. 3.5).
Figure 3.5 Type of bottom drafting rollers
Parallel flutes run along the roller axis and separated by a predefined
distance. The normally used flute density on ring frame bottom rollers is 5–6
flutes per cm. Helical flutes run at an angle to the roller axis, often referred as
spiral flues. They offer higher gripping area in comparison to parallel flutes
with the same density. Thereby provides better fiber control during drafting,
especially at higher speed and high draft levels. Knurled roller has raised points
distributed evenly throughout working area. Owing to its highest gripping

force, it is employed as a driving roller for the aprons. Modern long ring
frame operating at high speed with high draft ratio is provided with very high-
precision checkered or arrow groove patterns bottom rollers. They guarantee
constant, optimum drafting conditions even at the high speed.
The diameter of the bottom roller lies in the range of 27 mm (old) to
30–32 mm (new). They are driven positively from the main gear train at the
head end. So, a special roller section, extended at head end to carry the gears,
is needed to drive the rollers. Another special roller section is used at the tail
end where the worm drive for the traverse motion is located.
The bottom rollers are mounted on “roller stands” fastened at regular
intervals, equals to staff length on the roller beam. Bearings are provided
for rollers in roller housing, at each roller stand. Hence friction less and true
rotation can be assured. They also help in smooth and fault-free startup of
positively driven rollers. The ball bearings were used on older version for this
course. They are now replaced by needle bearing and further by pneumatic
bearings to support high speed and high draft system of new versions of ring
frame.
Apart from these few more auxiliary features are added to the design
of bottom rollers for precise drafting even at high speed with high draft
ratio. MMC Marzoli and RC-II ring frames are provided with chrome-plated
hardened and tempered bottom rollers. These rollers have opposite helix for
adjacent flutes. They prevent multiple end breaks due to lapping and also
supports in locating broken end. Toyoda RY-5 series ring frames are provided
with larger space at back roller stand. This helps in efficient air flow and
thus prevents fly from getting in. Rieter G 35 ring frame is provided with
arrow (Checker) pattern bottom rollers in place of helical flutes for better
fiber control. It is also equipped with X-fine motion. This motion permits high
draft ratio and thereby spinning of super fine count up to 250s Ne becomes
possible.
3.3.2 Top rollers

Ring frames operate with twin rollers, as top rollers. Twine roller is made
long enough to cover two consecutive bosses on the steel roller. They are
also known as compensating rollers and supported by the pressure arm (top
arm) at the neck portion (in the center) of the arbor. Arbor refers the rotational
axis of rollers. Being loaded by pressure arm during drafting is often said
to a pressure roller. Top rollers are made soft, by providing synthetic rubber
coating. This prevents crushing of fibers between two hard metallic surfaces
under an applied load. The basic engineering involved in their design is to

provide cushioning effect during drafting and also prevents fiber damage.
They are bigger in diameter to that of bottom rollers. This can avoid pattern
formation on soft pressure roller cover due to repeated point contact at the
same place. The normally used top–bottom rollers diameter combination in
the industry is given in Table 3.1.
Table 3.1 Top – Bottom Rollers Diameters Used in the Industry.
Roller diameter Front Middle Back Bottom

(mm)
OLD 27 25 27 (25-25-25)
New 30 27 30 (27-27-27)
32 27 32 (30-27-30)
Figure 3.6 Antifriction loose boss rollers
Antifriction shell-type rollers (Fig. 3.6), equipped with ball or needle

bearing, are used as top rollers now a day. They are available in two versions:
i. Fast Boss: Rollers, with the two pressure bodies/ boss at left and right
forming a rigid unit which can only be rotated together on movable
arbor. The main filed of application for such roller is where the bulk of
material involved is more. Drafting system on draw frame is provided

with this category of twin rollers. Except old version of Saco Lowell
ring frame, this type of roller system has not found application at ring
frame.
2. Loose Boss: Rollers, with the two pressure bodies/boss separately
mounted and able to rotate independently of each other on stationary
arbor. Preferred on the systems where bulk of material involved at
drafting system is less. So, they are found on speed frames as well
as on ring frames. Basic design of the rollers in this group consists
of a stationary arbor. It is provided with bearings along with housing
on each side. Thin metallic sleeves, known as shells, are fitted over
these bearing housing. A groove on the inside of the shell fits over
a snap ring in the housing to keep the shell properly located. Micro
seal at rear end of roll prevents loss of lubricants and ingress of dust
and lint into the bearing. The sleeve is having flutes either running
perpendicular to roller axis or knurled. These flutes provides desired
grip to the synthetic rubber cot mounted on it, thereby avoids undue
internal slippage while rotating. The cots of desired thickness in the
form of a short tube are fitted onto the bearing sleeve (shell) with a
certain degree of pretension and fixed in position. The cots are fitted
on shell with either metal or plastic bushes (old system) or with an
adhesive (new system), an operation that has to be performed with the
greatest care. Cot and shell together forms the working body of the
roller, often referred as boss.
A distinction is also made according to whether the roller bodies (boss) can
be removed from the shaft (removable boss), or are permanently attached to
the shaft (non-removable boss). The roller bodies are mounted on single-row
or double-row ball bearings. Additional cost of second bearing makes roller
costly but at the same time permits higher rotational speeds. Cost of the roller
is further affected by the type of bearings used. Life time lubricating bearings
are costly and normally employed on non-removable category of loose boss
rollers, e.g. SKF LP 303. The other category demands regular relubrication
after 30,000 operating hours or 5 years, whichever is early. Commercially
available grease guns are used for lubrication purpose. Removable boss type
rollers normally provided with this category of bearings. They are assembled
with end caps for the injection of grease via grease guns. No doubt the life time
lubrication bearing rollers are costly, as major share in roller cost arrives from
its bearing cost. Conversely, the shelf-life of such roller is also high. Thereby
modern high speed ring frames operating with high level drafts are equipped
with this costlier but maintenance free and better performance rollers.
3.3.3 Roller buffing

The synthetic rubber coating (cot) gets worn out by the continuous frictional
forces offered by fibrous material during drafting. They need to be buffed
from time to time. Buffing refers to the removal of material from the coating
with the help of special grinding machine. Normally it is carried out after each
3000–4500 operating hours of the ring frame. The amount of coating removed
from the cot diameter per buffing cycle lies in the range of 0.2 mm. The covers
should never be ground to a total thickness of less than 3.5 mm on repeated
grinding. Going beyond this limit makes cover too thin, and cannot provide
adequate elasticity under pressure. Thereby roller cot must be removed and
replaced with the new one thence after.
The method of removal of the old cot purely depends on the method
used for its mounting. The cots fitted with bush can be removed easily by
pressing tool. However, the cots fitted with an adhesive need to be cut open
and removed. The remaining of an adhesive on the shell is removed either by
mechanical treatment or by treating with solvents. Due care must be taken to
prevent damage to the costly bearings in this course.
Grinding action imparts roughening to the smooth surface top rollers.
This is liable to form neps on processing fibrous material during spinning,
if rollers re used directly after buffing. So, after treatment like application
of chemical film, acid treatment or UV light radiation, is done to smooth the
surface.
3.3.4 Roller cover hardness

The pressure roller covers are made of synthetic rubber. The hardness of
synthetic rubber cover is often described in terms of “Durometer reading”.
Durometer is an instrument used to record the resistance to the pressure
applied by its small point against the test material. The index so measured is
given as degree shore hardness of the compound under test. There are different
ranges of hardness:
• soft: 60–70° Shore
• medium hard: 70–90° Shore
• hard: over 90° Shore
Covers of less than 60° Shore are not usually of any use, since they are
unable to recover from the deformation resulting from the contact pressure
during a revolution of the roller.
Soft covers have a larger contact surface, and therefore enclose the fiber
bundle more fully, thus providing more effective guidance. However, they
also wear rather more quickly and have a greater tendency to form laps due
to the fulling effect. Harder covers are therefore used wherever possible.
However, increased control of this nature is an advantage at the delivery end,
where only few fibers remain in the bundle and these have a tendency to drift
apart. Covers with approx. 80–85° Shore are therefore usually used on the
back rollers and 63–67° Shore on the front rollers. Harder covers are also
chosen at the front, i.e. at the delivery end, for coarser yarns and manmade
fiber yarns owing to higher wear caused by stronger yarn. Even manmade
fibers show higher tendency to lap formation with soft delivery roller.
3.3.5 Fiber guidance devices

The amplitude of drafting waves can be minimized by increasing effective
control over the movement of fibers, especially short fibers. Increases in
inter fiber friction amongst the finest form of fiber strand in the process can
be achieved by controlled pressure on the fiber flux. The fiber bundle in the
main drafting zone consists of only relatively few fibers. There is virtually
no friction zone, and fiber guidance by rollers alone is inadequate. Thereby
special attention is paid to control movement of fiber flux during drafting,
the shorter fibers in particular. They have to be controlled in terms of speed
within the drafting zone. Special fiber guidance devices are therefore required
in order to perform satisfactory drafting. The following guidance options can
be envisaged for a ring spinning drafting system (Fig. 3.7):
Figure 3.7 Various types of fiber guidance devices at ring frame

i. Line guidance: A small aluminum or wooden roller often called

dummy or tumbler roller, presses with its own dead weight against
the bottom roller. The system normally found on conventional ring
frames. Since control on fibers has been imparted by the nip line
formed between dummy roller and carrier roller, this roller is also
referred as nip roller or fiber control roller and the system as line
guidance. The amount of inter-fiber and fiber- roller pressure purely
depends on roller weight, linear density of the material processed
and number of such pressure elements employed. However with
increased draft levels and machine speeds, this device becomes
obsolete.
ii. Surface guidance (two-dimensional): Surface of the roller or apron has
been employed for the purpose. Thus it replaces line control to two-
dimensional area control for the fibers under consideration. Earlier
engineering of shaping this concept in use was started with the use
of deflection rollers, then single aprons and nowadays double aprons.
All latest ring spinning machine drafting systems are equipped with
double aprons due to better fiber control attained at high draft levels.
INA-drafting system has employed combination of deflection around
back rollers, in addition to use of double apron system for imparting
better fiber control.
iii. Spatial guidance (three-dimensional): ‘Total positive control and
guidance of the volume of fibrous material’ concept has introduced
fiber channel in the commercial market. It was implemented in the
Ambler drafting system of the English worsted spinning process.
Optimum fiber control can be attained by this device only and thus
fewer irregularities can be observed in product. However, it is difficult
to work with, since the size of the channel should always be adjusted
to the bulk of the material. Volume guidance would be ideal with
moving surfaces rather than the stationary surfaces. Nevertheless, this
principle has found success for ring spinning of cotton. Double apron
drafting system is still the unbeaten concept used for fiber guidance
on ring frame.
3.3.6 Double apron drafting system

The double apron drafting system, the fiber guidance unit consists of two
aprons rotating with the middle driver rollers. The top apron must be pressed
against the bottom apron with controlled force in order to provide guidance.
For this purpose, there must be a gap between the two aprons at the apron
delivery end, known as tensor gap. This gap is precisely adjusted as per the
fiber volume by using different spacer plates, shoes, etc.
The aprons are made up of either leather (old) or composite technical
textile material (new). It has the width equal to the boss width of the driver
roller and thickness ranges between 0.9 mm to 1.1 mm. Endless apron is made
by tapered adhesive joint. According to the length of apron, they are classified
as either long apron or short apron.
The top aprons are always short. However, the bottom aprons can be long
aprons (Fig. 3.8(a)) or short aprons (Fig. 3.8(b)). Thus there are mainly two
categories of double apron drafting systems possible:
i. Double apron drafting system with long bottom apron and
ii. Double apron drafting system with short bottom apron
Figure 3.8 Double apron drafting systems
The former one is used invariably by all the drafting system manufacturers
due to its inherent advantages in terms of better performance and ease in
maintenance and cleaning.
i. Long apron: Steel Case Hardened Knurled roller is used as driver
roller for long apron (Fig. 3.8(a)). Metallic rounded tip bar is used as
guiding element for defining direction of apron in drafting zone. It is
known as nose bar. Apron tension has been controlled by either dead
weight loading (self-weight roll) or spring loading.
There is a less fear of chocking up of an apron due to more open space
available. Thereby run out will be true. Even replacement of an apron
can be done easily in the event of damage. Nevertheless, this apron
consumes longer length of costly apron material; it offset higher

initial cost by better performance and reduced efforts in maintenance
and cleaning.
Short apron: The short apron uses cradle as a guiding, supporting
ii.
and tensioning element (Fig. 3.9(iii)). The cradle is the light sheet
metal (old) or high strength non-deformable polymer frame or cage
fits partly round the roller bosses. It only creates a minimum degree
of friction on the top aprons. The flat slanting surface of conventional
cradle (Fig. 3.9(iii)) is deflected downwards on modern ring frame
of Rieter G33, G35 (Ri –Q-Deflection bridge). This change in the
working profile of the cradle and thereby short apron has ensured
closer spacing between front roller and middle apron. Thus improved
fiber guidance even at high draft ratio and speed can be attained.
Figure 3.9 Design features of short apron cradle
The sizing of the cradle (Fig. 3.9(i)) is done in terms of

i. Cradle length / cradle size (R): Distance between driver roller center
to the leading edge of the apron.
ii. Cradle extent (E): Distance between backend to the leading edge of
the apron.
iii. Cradle boss (b): Working width of an apron.
iv. Distance clip width (d): Spacing between cradle bosses for mounting
the distance clip.
v. Total width (Tw): Center to center distance of twine driver roller
aprons and
vi. Width (W): total cross wise length occupied by apron assembly.
Selection of the cradle is purely dependent on the fiber length. Cradle
length compatible with fiber length normally used in industry are as
follows:
• Short apron cradle (30–36 mm): Up to 40 mm fiber length
• Medium Apron cradle (40–46 mm): Up to 40–50 mm fiber length
• Long apron cradle (50–54 mm): Up to 60 mm
Number of elements involved in short apron is less, offering compact
structure. This permits closer setting to the front roller and offers better fiber
control. But the same makes it more inclined to become clogged with fiber
fly and dirt with the added difficulties in cleaning, if used as bottom apron.
Thereby adds to irregularities in output yarn as run out will not be true.
Even replacement of an apron cannot be done easily in the event of damage.
However, its initial cost is less due to reduced consumption of costly apron
material and number of assisting elements involved in its design.
3.3.7 Distance clip/spacer

Top aprons are pressed against bottom aprons by either spring or pneumatic
pressure of the top arms. Thus intensity of fiber clamping and fiber guidance
depends on this pressure and on distance between two aprons. The vertical
distance between front edge of top apron cradle and bottom apron nose bar
is defined an apron nip and denoted by letter ‘X’ (Fig. 3.9(i)). The desired
apron nip (X) based on type of fiber, fiber mass in main drafting zone, roving
count and type and dimensions of top and bottom apron, can be set by using
the spacer. It is a special anti-friction clip/s mounted at the center of cradles
at their front edges. They are developed by companies like Rieter and Sussen.
Hence these clips are designed to define vertical distance between apron
nips also marketed as distance clip by SKF. They are made of an extremely
wear-resistant plastic material and replaceable. Different thickness clips are
available to meet required apron nip value. Colour coding (Table 3.2) is given
to the different size spacers by the manufacturers for ensuring its correct
selection even by the unskilled labour.
Table 3.2 Colour coding of the spacer
Cradle spacer Apron mip (X) in mm

Green 2.5
Pink 2.75
Red 3.0
Orange 3.25
Brown 3.5
Grey 4
Yellow 5
Blue 6
Beige 7
Black 8
3.3.8 Roller stand

Roller stand (Fig. 3.10) is the supporting frame designed for housing drafting
system variables like bottom rollers, traverse guide and pressure arm. The
number of roller stands is fastened on the roller beam at regular interval as per
roller staff length on the roller beam. The staff length refers the linear distance
between adjacent roller stand and length of bottom roller section.
Figure 3.10 Basic design features of roller stand

The roller stands are made up of cast iron (on old ring frame) or aluminum
alloy (on modern ring frame). It has round or rectangular footed posts to born
the bearing for the bottom rollers. The roller stands made to incline at an angle
to the roller beam for the propagation of twist right up to the nip of front roller.
The roller stand angle varies between 30° and 45° for old version and 60° for
new version of ring frames. Its value has been defined as per the spinning
geometry of particular machine.
Front roller bearing is always kept at a fixed position on roller stand.
The rear rollers bearing are borne by the sliding bracket, fitted on the front
roller bearing housing via set screw. The rear rollers position can be altered
with respect to front roller, by altering set screw position in the slot. This
alteration is done to suit the staple length of fibers being spun. The setting
between middle roller bearing and back roller bearing is varied by set screw
connecting them together on the sliding bracket. A guiding slot is provided
behind the back drafting roller bearing for traverse bar. The traverse bar holds
trumpet shape roving guides and reciprocates within this slot. The function
of the traverse motion is to continuously move the roving guides from side
to side of the roller boss. Thereby the wear caused on drafting this fiber flux
is distributed uniformly over the large area of roller bosses. Thus it prevents
channel formation on soft roller boss and ensures its longer life span.
Nose bar and tension roller are used for the bottom apron apart from
the middle driver roller. A guiding slot between front roller and middle
roller is provided for supporting nose bar also. The support bar carrying
all the top arms is mounted in the slot provided at the back most end of the
roller stand.
3.3.9 Roller setting

Roller setting is basically defined in such a manner that when grip on the
bundle of fibers is released by one pair of rollers on one end, the next pair of
roller takes hold of their other end. The more precisely this exercise is done
during drafting, better will be the control imparted on the moving fiber flux.
However care must be taken that the fibers should not be hold at both the ends
simultaneously. So, consecutive pair of rollers must be spaced accordingly.
Single factor thereby should not be considered in defining the setting value,
but several factors have to play a decisive role. Some of them are:
i. Type of fiber and its characteristics especially upper quartile length,
nowadays 2.5% span length,
ii. Bulk of material processed, it refers roving size and its characteristics,
iii. Type of drafting system, etc.
Generally setting refers center-to-center distance of two consecutive

bottom steel rolls, with an assumption that top rollers are set exactly above
them. However this is not the common practice for the inclined plane top
arm drafting system. The bottom rollers are set as though the drafting plane
is horizontal. “X” and “Y” represent such front rollers and middle rollers and
middle rollers and back rollers setting values for bottom rollers (Fig. 3.11).
Figure 3.11 Roller setting
The top rollers are capable of moving in the slot of top arm. Usually they
are arranged to ensure the maximum control on the fine mass of fibers at high
speed. Usually front rollers are shifted towards front with respect to bottom
front roller by 2 mm (old) to 4 mm (new), referred as front roller overlap or
overhang. The middle top rollers or aprons have given backward shift from the
respective bottom one by 2–4 mm, often said as rear over hang or an underlap.
Sometimes back top rollers have also given a rare overhang of 2–4 mm, to
ensure better fiber control at the entry point of roving to the drafting system.
The overlap of the front roller in addition also shortens the spinning triangle
by advancing the nip line, which has a correspondingly positive impact on
ends down frequency. Thus, the mathematical equation (Eq. 3.1) for front
zone setting (A) is as follows:
A = a + X + b (Eq. 3.1)
Similarly, Equation 3.2 represents the setting value for back zone
setting (B).
B = Y – b + c (Eq. 3.2)
INA Company has offered another roller configuration, so-called V Draft
drafting system as mentioned earlier. In this case the rear top roller is shifted
to the rear on the bottom roller. The larger wrapping arc (Fig. 3.12) results in
an additional fiber control zone. However, it can also result in a wider spread
of the fiber ribbon.
Figure 3.12 The INA drafting system
3.3.10 Loading of top drafting rollers

Top drafting rollers are driven negatively via frictional contact with bottom
rollers. Thereby top rollers need to be pressed against them to acquire the
same speed for better fiber control. There are three types of roller loading
systems in use on ring spinning machines. The difference lies in the media of
loading used for rollers. They are:
i. Spring loading: The system used by the most of the manufacturers on
conventional ring frame. Example: SKF PK- 225, Sussen UT-600 etc.
ii. Pneumatic loading: The system adopted by most of the modern high
speed and high draft ratio ring frame. The leading manufacturers are
Rieter and Texparts in the field. Example: Rieter FS 160 P 3.1.
iii. Magnetic loading: The developer of the system is Saco Lowell. But
this is only the conceptual system not found success in the commercial
market.
Loading supports are required for mounting the top rollers using the
first two types. These bearing arms are attached to continuous shafts or tubes
mounted behind the rollers on roller stand. They can be opened and closed
by means of levers in order to reduce and increase the loading, respectively.
The entire assembly is referred as top arm. The top arms are designed for
single-handed operation. Their basic duties remain same, although they differ
in terms of their design features.
Duties of top arm

i. The basic duty of the top arm is to hold the top rollers securely and
strictly parallel and in alignment with the bottom rollers.
ii. It should transmit the load to the bottom rollers without undue friction.
iii. It should give provision for accurate top roller settings.
iv. It should offer reliable base for ensured fiber clamping and guidance.
v. It should offer ease of opening and closing of top arm. But these
movements of top arm must not affect adversely top roller positions
with respect to yarn path.
Design features of top arm

The entire set up is made up of heavy sheet metal for conventional spring
loaded top arms. But the modern high speed ring frames use light weight and
sturdy steel in its replacement. This helps in reducing burdensome load on
roller beam in addition to higher shelf-life of the system.
The top arm structure is invariably composed off three basic working
elements; bracket, frame and pressure lever, irrespective of its type (Fig. 3.13).
However, their shape and supportive features gets altered from manufacturer
to manufacturer according to loading mechanism. But their role in drafting
mechanism remains same. The brief mention about them is appended below.
Features of SKF-spring loaded top arm included as an example. Another
mechanical top arm of Sussen is also having many of the features identical. But
wherever they differ it is enough to influence performance. The engineering of
pneumatic top arm is done to overcome limiting features of classical one and
further to impart simplicity. So, the focus of discussion is accordingly directed
in the proceeding section.
Working elements of top arm

(a) Bracket: It is a rounded edge rectangular sheet metal hollow
channeled bracket in case of mechanical top arms (Fig. 3.13(v)). It
is mainly designed to hold the top arm securely on the support bar.
The support bar is the solid circular rod, mounted on the roller stand
behind the bottom rollers in bearing housing. Bracket is punched with
circular hole near about its bottom end. The diameter of circular hole
is kept bigger than the bore diameter of the support bar. This permits
pendulum / top arm to slide past easily up to required position on the
support bar. Such loosely mounted top arm is retained in position by
set screws. The entire exercise makes mounting and replacement of
mechanical top arm undue complicated.
Figure 3.13 Basic working elements of top arm (SKF PK 225)
To overrule this limitation, the rectangular shape bracket is replaced

by hexagonal split bracket for pneumatic top arm (Fig. 3.14(a)).
This change makes mounting and replacement of top arm on support
bar easy for two-piece bracket. It is secured in position via two set
screws. The support bar is stamped from steel sheet and is mounted
on a continuous hexagonal section tube behind the rollers. Thus use
of hexagonal hollow bar in place of solid cast iron rod, reduces higher
weight bearing burden of roller beam.
Mechanical top arm brackets are also provided with height adjustment
arrangement for front drafting roller (Fig. 3.13(v)). The vertical height
of front top roller from the bottom one in loaded condition determines
amount of load transfer. Set of height set screw and locking screw
is provided for the purpose. Height set screw facilitates in altering
angular position of bracket with respect to support bar. Thus varies
angular position of frame fulcrum on the bracket. This sets front roller
height to and forth about its bottom one, to alter its load. The required
position is retained by the locking screw. This setting needs to be
done manually and head wise, liable to introduce human-associated
errors. No such complications arise with pneumatic arm.
(b) Frame: It is a hollow channeled frame with slot/s cut at its top surface.
Loading elements and their accessories, viz., the top roller saddles
fit tightly into the top arm frame body. Thereby keeps them strictly
parallel and in perfect alignment with bottom rollers (Fig. 3.13(iii)).
Design features of frame for mechanical and pneumatic top arms
are having vast differences mainly due to their working concept.
Mechanical top arm is provided individual roller saddle fitted in
the slot of the frame with set screw. Each saddle incorporates roller
retainer to receive top roller arbour at its neck portion. The roller is
well secured in position by roller retainer flat spring. The guiding
groove (slot) gives provision to slide saddle to and fro for altering
the roller setting to suit the fiber length processed. Hence, front roller
position always remains unaltered for smooth twist flow. So, no
provision is given to alter front roller position in top arms. Sussen top
arm is provided with scale graduated in centimeter and millimeter,
parallel to the guiding groove. This helps in reading off roller setting
values directly.
Pneumatic top arm is provided with two saddles. One carries front
and middle rollers retainers, whereas second one carries back roller
retainers. There is a provision to alter middle and back roller retainer’s
positions in the guiding grooves of saddles. This facilitates to
accommodate different sizes of cradle. Both the saddles are provided
with three similar size holes punched on their surface. Saddles can
be clubbed together by matching these holes and inserting pin in one
of the hole as per requirement. This pin acts as pivotal point for front
and back roller. Such united saddles are then attached with frame via
second pin. This pin is inserted in one of the three holes punched on
both of them. This connection point again becomes a pivotal point but
now between back roller and group of front rollers (front and middle
top rollers).
(c) Loading element: It is an integral part of the frame only for both
the categories. The individual roller is loaded either by mechanical
means, viz., spiral spring (Texparts PK 225), Leaf spring (Sussen UT
600) or pneumatic pressure (Rieter FS 160 P 3.1).
(i) Spiral spring loading: SKF system uses spiral spring loading
system. Springs load roller saddles and based on its leverage,
load gets transfers to roller axis (Fig. 3.13(ii– iii)). Thus it gives
indirect mode of load transfer. A spring, sometimes two on the
front roller – presses the top roller against the bottom roller. In
the case of SKF, special load selector arrangement is provided
only for the front roller. Its loading pressure can simply be
altered with the help of eccentric load selector in three stages
by means of a tool known as wrench (Fig. 3.13(iv)). Colored
marks indicated the set loading stage. Rest of the rollers
spring pressure can be altered by separate set screw for each.
Loosening or tightening the screw can decrease or increase
the pressure respectively. But again this is head wise and in
that further roller wise manual setting, purely influenced by
individuals expertise.
(ii) Leaf spring loading: SUESSEN top arm uses refined steel leaf
spring bend at front leading edge to form plate, for loading
(Fig. 3.13(ii)). This top arm is known as the UT type. The plate
spring applies pressure directly on the roller axis. The plate
formed at the point of application also acts as damper against
roller vibration, normally occurs at high-speed drafting and
prevents roller from becoming eccentric. Spring pressure can
be altered similar to SKF with the help of individual set screw
provided for each saddle on the frame.
However cheaper, the spring loading system undergoes major
limitations. They are:
• Top arm loading pressure can be changed by set screw,
purely based on manual judgment and influenced by person’s
expertise.
• Spring looses strength with respect to time and introduces
pressure variations and thereby adversely affects quality of
yarn.
• Head wise setting mode adds to spindle-to-spindle variations.
• Roller neck gets worn out of and also roller deflection occurs,
due to abrasion with spring or loaded retainer. These reduce
roller life and reliability of alignment with bottom rollers.
Pneumatic loading: Rieter FS 160 P 3.1 is provided with
(iii)
pneumatic loading. The support bar is stamped from steel
sheet and is mounted on a continuous hexagonal section tube
behind the rollers. The tube contains the compressed air hose
connected to a central compressor unit via pressure gauge.
When pressure lever is lowered, pressure finger carried by it
forced against hosepipe via a cam. Thus it works against the
compressed air and generates pneumatic pressure (load), with
respect to its connection point with the frame. This pressure is
transferred to the pivot point of two saddles attached with the

frame. Hence saddles are carrying all three top roller retainers
as mention above, the pressure is applied to these rollers. The
two saddles here form a double lever system. There leverage
varies as per the position of a pin in one of three superimposed
holes of group of two saddles with frame. This pin acts as
the pivot at the junction point of saddles with frame (Fig.
3.14(a)). Thereby air pressure distribution on three rollers
varies according to their leverage with respect to this pivotal
point. The total air pressure coming from the compressed air
hose and acting on the entire pressure arm is applied more
strongly either to the back roller (front hole) or the two front
rollers (back hole) as per the pin position. Pressure can also
be distributed differently between the two front rollers via
a second pin. This pin connects both the saddles together at
their superimposed holes and acts as a pivot for front rollers.
Connecting via first hole increases front roller pressure and
third hole for middle one. Normally adopted load settings for
short staple, medium staple and long staple are given in Fig.
3.14(b). Thus it can be used for wide variations in the fiber
length, only by replacing only cradle set, altering pin setting.
Thereby this arm is also referred as universal top arm. Total
load of entire drafting system can be varied simply by changing
incoming compressed air pressure at air hose via a reducing
valve at the tail end of the machine. The pressure value can
always read off directly from the pressure gauge provided in
air supply line.
The major advantages born while working with pneumatic
loading system are enlisted below:
• Load setting is simple, precise and very rapid due to
centralized system used for air pressure change. Considerably
reduces skilled labour compliment involved in the process.
• Constant air pressure with respect to time ensures uniformity
of yarn quality produced.
• Simple and rapid pressure reduction to a minimum in the
event of machine stoppages, so that the roller covers are not
deformed during prolonged interruptions to operations.
• Prevents roller deflection and thereby ensures alignment
with bottom rollers.
Figure 3.14 (a) Working elements of pneumatic top arm (Rieter FS 160 P 3.1)
(d) Pressure lever / pendulum lever: It is simple channeled lever fulcrum

at its rare end on the bracket. There is no marginal difference in the
design features of mechanical and pneumatic pendulum lever, except
in terms of material. Pressing down the lever brings pendulum lever
and thereby top rollers into weighted state. Similarly lifting of the
lever releases load and prevents damage to the soft top rollers. There
is always a provision to open and raise the arm to its upper position,
where it can held securely in place by loading device. Opening angle
between pressure lever and central line of drafting system ranges
between 30° (old) and 45° (new). This brings ease in mending of
the broken end. Additionally, it also covers locking screws and guide
grooves of frame against fly accumulation.
Figure 3.14 (b) Load setting of pneumatic top arm (Rieter fS 160 P 3.1)
3.3.11 Roller cleaning mechanisms

Drawing action at the main drafting zone releases residual dust and trash.
They drop down due to their own weight. At the same time, the short fibers
separated from the bulk and not carried forward along with the main bulk
of fiber tend to stick with the roller surface, especially soft top rollers. If not
cleared immediately, likely to result in roller licking and further end down and
added maintenance. Roller licking refers the wrapping of fibers around the
roller (top/bottom) instead of following main stream. Thereby some surfaces
are arranged to contact the rollers and aprons to keep them clean. These
surfaces are called “clearers” and the waste collected by them as “clearer
waste”. The clearers provided for cleaning top rollers or top apron are known
as “top clearers”. Similarly clearers employed for the bottom rollers and
bottom apron are known as “bottom clearer”.
Clearers can be in the form of roller or board, and also either stationary or
revolving. Normally on ring frame revolving roller, clearers are used for top
as well as bottom rollers and aprons except bottom front roller. The revolving
clearers are basically flannel covered wooden rollers. They are bigger in
diameter than the working boss of the roller, normally 40–50 mm and as long
as the roller section. They are supported on the roller stand pins for the bottom
rollers and on roller hooks fitted on top arm for the top rollers. Common
clearer roller is employed between back and middle rollers. The clearer roller
used for the front top roller is often known as “Scavenger roller”. Cleaning on
the bottom front roller is done by pneumatic means.
Pneumafil waste
The drafted ribbon composed of all long and open fibers can go to the waste
from the front roller nip in the event of end break. So, specially designed
pneumatic system is provided for collecting these good fibers separately from
the rest of the waste generated at ring frame. Hence the system collects waste
pneumatically, known as pneumafil. The waste so collected is referred as
‘pneumafil waste” or “bonda waste”. As mentioned above it is composed off
all long, good (white) fibers in an open state, so often referred as “soft waste”
as well as “white waste”. This good fibers waste is a reusable waste even
for the same mix but never been added fully. Because undue beating of long
and open fibers, at blow room, leads towards increased yarn irregularities on
higher add on. Situation becomes more crucial with finer count spinning. So,
proportion in mix is always kept less for finer count but more for coarser count
spinning. Efforts are always made at mills to keep such waste generation as
low as possible by controlling end break rate minimum and ideally zero.
Pneumafil system
Figure 3.15 illustrates schematic diagram of one of the pneumafil set up used
on conventional ring frame. It collects pneumatically drafted ribbon on end
down from the front bottom rollers nip of the entire ring frame at one station.
So, the set up begins from front roller and ends with collection box, placed
at the tail end of the ring frame. The required air pressure is generated by
pneuma (suction) motor placed in pneumafil chamber. The circulation of the
suction air is done by the network of ducting between front rollers and suction
fan. Working principle of the system is briefly appended below:
Separate spring-loaded suction flute is provided for each head. It is kept
pressed against each bottom front roller. It draws away the ribbon of fibers
emerging from the front roller nip of the ring frame whenever end break occurs
at any head. Collected fibers follow through the extension pipe, connected to
central receptacle duct. It collects such ribbon of fibers on end break for the
entire ring frame. The end point of this duct is connected with separation
chamber, provided at the tail end of the frame. Here the fibers are separated
from the air by the conical screen. The air is expelled to the atmosphere and
waste fibers are dumped into collection tray placed at the base of pneumafil
chamber. They are collected manually via waste collection door at regular
interval of time.
Figure 3.15 Conventional pneumafil
The suction fan (pneuma) motor works at fixed rpm in conventional

pneumafil set up. Thereby suction values achieved is fixed and has no relation
to the density of fiber flux (dependent on type of material or count being
processed) and spindleage. Results in undue higher working pneumafil
pressure. This leads to suck higher waste/ bonda waste and adversely affects
yarn realization. In order to overcome these limitations, modern high speed
ring frames are equipped with inverter controlled pneumafil motor (Fig. 3.16).
Suction pressure is set by varying inverter control pneuma motor speed in
relation to expected fiber flux flow through the system as per input data. It
purely depends on spindleage of the machine, count, and raw material being
processed. This pressure is constantly monitored by pressure transducer and
data feedback to inverter (motor speed regulating system). Thus it reduces
power consumption and prevents undue good fiber loss considerably. The
control on good fiber loss is of prime importance for high speed operating
modern machines even at the added cost of inverter control system of waste
collection.
Figure 3.16 Modern pneumafil with suction pressure monitoring system
3.3.12 Drive to the drafting roller

Draft is one of the major jobs performed by the ring frame. Precision of
drafting depends on the accuracy of drive transfer without causing slippage.
Conventional system
The system uses cast iron gear train to drive drafting rollers from the main
drive. Draft gearing is the term relates to the gear train utilized for driving
drafting rolls only. One such schematic diagram for conventional draft
gearing is illustrated in Fig. 3.17. This gear train includes two change wheels,
viz. draft change wheel (DCW) and draft change pinion (DCP). Draft change
wheel is used to alter draft of the system, whereas draft change pinion is used
to widen the applicable draft range value of the existing system for the given
DCW. Thus the system demands larger inventory of change wheels to deal
with required draft ranges.
Figure 3.17 Draft gearing used on conventional ring frame
Amount of draft employed by the drafting mechanism is dependent on the

hank of the roving fed and yarn count delivered by the front roller. It is known
as mechanical draft. Thus,
Yarn count delivered by front roller
Mechanical draft = (Eq. 3.3)
Roving hank
Expression used for indirect yarn numbering system
Or
Roving hank
Mechanical draft = (Eq. 3.4)
Yarn count delivered by front roller
Expression used for direct yarn numbering system
Hence, yarn count on the bobbin become coarser than that delivered by
the front roller due to twist contraction. Since amount of twist inserted is
highest at ring frame, the contraction value cannot be ignored. Thus, actually
applied total draft value for getting final delivered product out of fed roving
fineness is different than the mechanical draft calculated by Equation 3.3. It is
dependent on yarn count at the bobbin and roving hank and can be derived by
the following relationship:
Yarn count delivered on the bobbin
Actual draft = , for indirect yarn
Roving hank
number (Eq. 3.5)
Or
Roving hank

Actual draft = ,for direct yarn
Yarn count delivered on the bobbin
number (Eq. 3.6)
Whereas,
100 – % Twist contraction
Yarn count at front roller = Yarn count at bobbin ×
100
(Eq. 3.7)
for indirect yarn numbering system and
100 + % Twist contraction
Yarn count at front roller = Yarn count at bobbin ×
100
(Eq. 3.8)
for direct yarn numbering system
The setting of total draft for the drafting system is done on the basis
of mechanical draft only. Because draft relates with the surface speed ratio
of part handling delivery length (front roller) to that of part handling feed
material (back roller). Thus draft on the machine is nothing else but a surface
speed ratio of front roller and back roller.
Surface speed of front roller
Q Total draft = (Eq. 3.9)
Surface speed of back roller
Relative calculation is done by assuming unity for back roller rotation.
The length delivered by front roller is calculated and divided by the length fed
by back roller for its unit rotation.
Some important terms:
Draft constant (DC) is the total draft obtained for the unity draft change
wheel. The value of draft constant is used to determine the draft for known
draft change wheel gear or other way round, to evaluate draft change wheel
value for the known draft.
Break draft (BD) represents ratio of surface speed between front and
middle rollers. It is used for opening up the roving twist or preparing twisted
fiber strand for major draft. Higher the roving twist higher the break draft
employed for. It can be calculated and changed by replacing existing break
draft change wheel (BDCW) with appropriate size gear.
Main draft (MD) refers the major attenuation given to the parallel strand
of roving to get desired fineness yarn at front roller. Thus it represents ratio of
surface speed between front roller and middle roller.
The entire mathematic evaluation of various measures of draft can be well
understood by the example.
Example: Calculate total draft, draft constant, break draft, major draft
for the draft gearing given in Fig. 3.17. Also calculate draft change wheel
required to spin 40s Ne yarn out of 0.8 s Ne hank fed roving (Per cent Twist
contraction = 5).
33 × 21 × π × 25
Break draft = = 1.086
25 × 29 × π × 22
29 × 25 × 120 × 121× π × 22
Major draft = = 24.31
21 ×33× 50 × 11× π ×25
33 ×21 × π ×25
Break draft constant = = 31.5
25 ×1× π ×22
120 × 121 × π × 22
Total draft = = 26.4; and also
50 × 11 × π × 22
Total draft = Break draft × Major draft = 26.4
120 × 121 × π × 22
Now, draft constant =
1 × 11 × π × 22
= 1320; true for given DCP = 120
As, 40s Ne is on the bobbin with twist contraction of 5%. Since yarn
count is given in Indirect (English) system, so yarn count at front roller can be
calculated as;
100 + 5
Yarn count at front roller = 40 × = 42
100
Therefore, total draft required for spinning 40s Ne out of 0.8s Ne hank
roving is
42
Total draft = = 52.5
0.8
According to relationship
Draft constant
Total draft =
Draft change wheel
Draft constant
or Draft change wheel = (Eq. 3.10)
Total draft
The required draft change wheel in present case is,
Draft constant 1320
Total draft = = = 25.15T ~ 25T
Draft change wheel 52.5
So, 25T draft change wheel (DCW) should be used to get desired 40s Ne
yarn out of 0.8s Ne hank roving fed.
Now it is clear from this example that exact draft value is difficult to meet
in many a case in this type of set up. As gear with partial teeth (25.15T) is not
possible, it needs to be rounded off to the nearby full number (here 25T) as
per math’s rule. Such draft gearing gives draft either on higher side or lower
side as per the position of change wheel gear in the train (driver/ driven). As
in the given example rounding off of gear value gives draft of 52.8 instead
of 52.5 desired. Thus, actual yarn spun is of 40.13s Ne instead of desired 40s
Ne fineness. This deviation in yarn fineness is attributed to the limitation of
exactifying gear value.
The entire discussion highlights following limitations of convention drive
set up:
(a) Requires different size gears for BDCW, DCW and DCP while
working with different roving twist and yarn size, increases need for
inventory of parts.
(b) Change of break draft or draft demands mathematical calculations.
Adds to time delay and associated human error.
(c) Due to limited availability of alternatives with two change wheels,
allowable draft range gets limited, limits spinning range of ring frame.
(d) Change over is time consuming, tedious, increases downtime of
machine. It is also suffering from associated human errors and
rounding off errors in mathematically derived gear values. Thus
liable to vary yarn size more from the nominal one.
(e) Long-gear train composed off heavy cast iron gears adds to power
cost. Also demands regular maintenance, increases machine down
time also.
(f) Spur gears used for the drive have incorporated inherent slippage in
drive, varies the roller speed from the theoretically set one results in
draft variation.
Drive set up with combination draft change wheel

Combination draft change wheels (A-B-C-D) system was introduced in the
middle edge ring frames like LMW G5/1. Four change wheels were used in
place of one (DCW) or two (DCW & DCP). The system was incorporated
with readily available data for draft change wheel combinations applicable
for very wide range of draft range possible on a given machine. The range
covered up very minute to wide changes in draft value without rounding off
gear value due to four options of change wheels; thus, eliminated rounding off
errors of conventional set up. Apart from that change over became speedy and
precise in the absence of manual mathematical calculation.
Timer belt and pulley drive has replaced long gear train used for the
front roller drive received from the mains. Thus not only inventory cost but
also power cost gets reduced. The timer belt drive system has zero slippage,
ensures drive transfer. Light weight steel gears have replaced classical heavy
weight cast iron gears, thereby given low maintenance and longer shelf-life.
All together has allowed high speed draft with high draft ratio possible on
ring frame. High draft ratio has permitted to spin with coarse feed hank.
Speed frames can operate at high speed for coarser roving. Thus increased
production per flyer frame and reduced number of flyer frames needed at the
back, added to process economy.
Here high speed drafting refers drafting done at increased delivery speed
but at the same speed ratio of rollers. So, fineness of feed material and output
yarn remain identical. High draft ratio means drafting done by maintaining
the same delivery rate but at increased speed ratio of the rollers. Thus for
producing yarn with similar fineness, coarser roving can be used.
The system still suffering from the following limitations:
(a) Initial cost of the system is high; no doubt its payback period is less.
(b) Still manpower is used in gear change, although simplified liable to
introduce human error.
(c) Single motor situated at head end is used for the entire machine drive.
Differential torque developed between head end and tail end likely
to cause twisting of bottom rollers’ shafts. The situation becomes
more critical with longer length (1600 or more spindles) machines
operating at high speed.
Synchronous multimotor drive for drafting rollers

Separate motor is used for each roller on latest too long high speed ring
frames, e.g. Rieter G 35 ring frame (Fig. 3.18). Two motors per roller are
employed as number of spindleages is doubled than the previous version to
prevent twisting of shaft. Motors are situated on each side, one at the head
end and another at the foot end of the machine. Motor transmits drive from
the respective end to the center of the machine only. Thus one motor controls
half of the total spindles, almost equivalent to single motor operated 800
spindles ring frame. This prevents bending of roller under differential torque.
Synchronous motors drive is controlled by frequency converters. Main draft,
break draft values can be set readily by changing motor speed directly. Since
all the motors are interfaced with computerized frequency converters, it can be
done readily by touch screen control. Fingertip control system for the motor
speed has eliminated need for mathematical calculation and imparted due
accuracy. Hence aprons are used at middle bottom rollers position, more and
precise force transmission is required at this point. Thereby on latest versions
of ring frame like Rieter G 35, additional motor is provided for middle roller
at the center also. Owing to the mode of functioning, the system often referred
as, ‘frequency converter controlled individual draft roller drive system’. No
doubt capital investment for the system is much higher.
Figure 3.18 Frequency converter controlled individual draft roller drive system
3.3.13 Significance of drafting system inclination

Drafting system is inclined at 30–45° on old ring frame and by 60° on new
one. Inclination of the drafting system offers benefits at two major ends:
i. Economy of spinning by saving in floor space and
ii. Ensures twist flow closer to the front roller nip.
Floor space saving: Machine width gets reduced with the inclination of
the drafting system. So, number of ring frames accommodated in a given mill
space will be high. Saves the total floor space occupied and thereby capital
cost of spinning.
Better twist flow: Turns of the twist are generated at ring and traveller. The
twist then propagates from traveller to the nip of the front-drafting roller. The
twist must run back as close as possible to the nip line of the front rollers. But
in actual practice it never penetrates right to the nip. This is mainly attributed
to wrapping of bundle of fibers around front bottom roller while emerging
from the roller nip (Fig. 3.19). The contact made with front roller acts as
twist barrier and will not allow it to propagate closer to the front roller nip.
This always results in the twist less triangular bundle of fibers often called
“spinning triangle”.
Figure 3.19 Influence of roller stand inclination on spinning triangle
The angle formed between exit and entry point of fiber bundle with the
center of the bottom front roller is known as angle of wrap. It varies in inverse
relation to the inclination of the drafting system. Higher the angle of wrap,
more it will act as twist barrier and twist flow gets restricted earlier before
reaching to the nip of front roller. Hence, larger spinning triangle forms longer
length of weak band and increases end breakage rate.
On the contrary, higher inclination of the drafting system makes spinning
triangle too short. Edge fibers undergo longer path line, escapes from the
proper binding of the twist. Short fibers do not bind at either end and lost into
atmosphere as fly, whereas long fibers get bind at one end only leaving other
end protruding out from the yarn surface; thus produces hairy yarn.
Proper selection of drafting system inclination must be done as per desired
spinning geometry. It should give good binding of edge fibers with yarn
matrix to avoid hairiness and fly generation, also there should be minimum,
ideally zero, end breaks throughout the doff.
3.4 References
1. Carl A. Lawrence (2003). ‘Fundamentals of Spun Yarn Technology’, CRC
Publications.
3. Eric Oxtoby (1987). ‘Spun Yarn Technology’, Butterworths & Co. Ltd., London.
5. Klein W. (1987). ‘The Manual of Textile technology: Vol. I –The Technology of Short
6. Lord P.R. (2003). ‘Hand Book of Yarn Production: Science, Technology and
Economics’, Taylor and Francis.
7. www.rieter.com/.../ring...drafting-system/.../double-apron-drafting-system.
[Accessed on 1 June 2014].
8. http://www.components.oerlikontextile.com, [Accessed on 1 June 2014].
9. http://www.suessen.com/fileadmin/suessen/products/EN/ring-spinning/hp-drafting/
technical-memos/hp-a_410_top_weighting_arm_sct3214ne_1106.pdf, [Accessed on
1 June 2014].
10. http://www.nptel.ac.in/courses/116102038/23, ‘Latest Development in Ring Frame -
nptel [Accessed on 1 June 2014].
11. http://www.academia.edu/3773342/Developments_in_drafting [Accessed on 20
September 2014].
4
Twisting mechanism
Abstract: Contribution of creel and drafting section in the production course of

ring spinning is well defined in the last chapter. Basic role of various machine
components involved in those section along with their engineering design to meet
the requirements are well summarized. Even brief mention about the changes
in their features with respect to technological changes are briefly introduced.
Similarly this chapter is going to deal with spinning section. Twisting of drafted
strand is carried out with ring–traveller set up to meet desired yarn characteristics.
Key words: Twist, lappet guide, thread guide, balloon, spinning angle, spinning
triangle, anti-ballooning devices, separators, balloon control ring, balloon height,
ring, ring flange, flange number, web, angle of pull, winding on angle, running
in, ring rail, ring holder, traveller, traveller count, center of symmetry, center of
gravity, traveller canting, traveller limiting speed, traveller flange, wire profile,
elliptical ring traveller, SU-ring, orbit ring traveller, twist direction, twist multiplier,
staple length
4.1 Introduction
Drafted ribbon emerging out of front roller nip at ring frame is the finest
amongst all outputs of drafting system over the entire spinning process.
Thereby additional strength is imparted by compacting constituent fibers of
ribbon together by inserting twist. Ring–traveller set is used for generating
desired turns of twist. However, some bulk (cover) and elasticity of the strand
gets sacrificed in the course. So, amount of twist inserted gets vary for different
end uses. Such yarn need to be wound on a suitable size package, compatible
with existing as well as next machine set up in sequence for ease of material
handling. Even winding needs to follow peculiar pattern again suitable for
next process in a sequence. The brief mention about various machine parts
involved in the entire course of spinning, winding and bobbin building is
given in this chapter.
4.2 Twist mechanism in ring spinning

Spiral configuration acquired by the constituent fibers around the yarn axis
is referred as twist. It binds the parallel bundle of fibers in the drafted ribbon
to obtain desired strength value and prevents tendency to fray apart. A brief
mention of twisting mechanism used on ring frame is appended below:
A low-twisted bundle of parallel fibers (the roving) is fed to the drafting
zone. The difference in surface velocity of the front (faster) and back (slower)
drafting rollers will attenuate it to a desired fineness thinner strand of parallel
fibers, under the control of the double aprons. The thin strand of parallel fibers
emerging from the front rollers is then simultaneously twisted by upright
twisting. The turns of twist are generated by the ring–traveller combination.
Where, ring is acting as a track for the traveller, roaming on its periphery. One
rotation of traveller earns one turn of twist for the drafted strand. Traveller is
driven negatively by the pull of yarn generated due to the difference in spindle
speed and winding speed (front roller delivery speed). The twisted thin strand
of fibers, now called a yarn, is threaded through a traveller and a yarn guide and
balloons out between these two elements during normal spinning. The twisted
yarn is then wound onto the bobbin or yarn package (i.e., cop) mounted on a
driven spindle (Fig. 4.1 (ii)). The bobbin is encapsulated within the rotating
balloon formed between yarn guide and ring–traveller.
Figure 4.1 Twisting mechanism and its variables
4.3 Working elements of twisting mechanism

The main variables of twisting mechanism are front rollers, lappet guide,
ring–traveller, spindle and cop. Since yarn bulges to form balloon between
Twisting mechanism 51
lappet guide and ring–traveller, induces yarn tension. This tension should not
exceed yarn strength, otherwise results in end down. Balloon tension control
devices like Anti Balloon Control (ABC) ring and separator are employed for
the purpose many a times. But they are not a mandatory feature of twisting
mechanism. Either both or one of them is used as balloon tension control
device for imparting spinning stability.
4.3.1 Lappet guide

Drafting system is situated in an incline plane and spinning/twisting elements;
ring–traveller in the vertical plane. Thus the first step in twisting process is
to change over the working plane of the material. Thereby next to front roller
nip, drafted strand is led to a lappet guide eyelet, placed in perfect alignment
with the center of bobbin, spindle and ring (Figs. 4.1 (ii and v)).
Lappet guide is basically a yarn guide but playing a crucial role in
ring spinning. So, its basic functions need to be identified first to justify its
importance as well as structural characteristics. They are:
1. The thread guide is acting as guide during changeover of the plane,
viz., inclined drafting plane to vertical spinning plane.
2. Its alignment with spindle decides symmetry of balloon and thereby
spinning stability.
3. Its position with respect to front roller decides spinning triangle and
thereby yarn quality as well as spinning stability.
4.3.1.1 Structural features of lappet guide / thread guide

Lappet guide due to its simulation with pigtail shape, it is often said as pigtail
guide. Hence it has to carry out more than guiding yarn during spinning it is
made up of three parts (Fig. 4.1 (i)):
i. Thread guide
ii. Lappet
iii. Thread guide rail
Thread guide: The thread guide is made up of round steel wire of 4 mm
diameter with a very smooth surface. The guide eyelet is formed by bending
the wire around a circle, in which the outer end of the wire overlaps the start
of the circle for about 90 degree. The diameter of an eyelet so formed is of 5–6
mm, to prevent retardancy to the twist running up to front roller nip. The wire
is then bent downward and outward. Slanting downward portion of guide
wire has notch just above the bottom end, acts as slub catcher. The straight
portion of the wire is known as a shank, set in the slit of lappet by setting
screw. The guide wire is adjustable in the slit for desired alignment with the
spindle, bobbin and ring. Guide eye is either easy threading or self-threading
in nature.
Lappet: Lappet is designed to support the thread guide. It is a flat square
or rounded square metal plate. Its back end is hinged on the thread guide rail
for lifting it independently, primarily for piecing up. Spacing between the
adjacent lappets is enough for the passage of the separators during traversing.
Thread guide rail: Thread guide rail is either a continuous round roll
or flat rectangular cross section metallic strip. One rail per side, of the ring
frame is provided to support the respective group of lappet guides. It is kept
in housing just in front of roller beam, with the top surface about level with
the upper surface of the roller beam. Handle is fitted at each extremity, to lift
half of the guides on a one side of the frame simultaneously. This is mainly
required at the point of doffing.
4.3.1.2 Traversing of lappet guide

The thread guide rails along with lappet guides can be moved in synchronization
with ring rail during bobbin build up. Two types of movements are earned by
the group:
• Continuous raising and lowering during layering traverse / traversing
of ring rail and
• Continuous upward lift but by small amounts as switching traverse/
advancement.
These movements prevent the differences in balloon height from
becoming too large between the individual ring rail positions (Fig. 4.1 (iv)).
Otherwise results in higher yarn tension variation. This would arise, with
correspondingly negative effects on ends down frequency and yarn properties.
4.3.1.3 Thread guides centering

It must be checked from time to time by means of a spindle gauge fitted on the
spindle. The tip of the centering pointer must point to the inside edge of the
eyelet (Fig. 4.1 (v)). This ensures the desired thread passes through the inside
edge rather than the center of eyelet. Thus prevents thread guide to act as a
twist barrier during twisting.
4.3.1.4 Influence of lappet guide position on spinning geometry

The guide is usually located in the horizontal plane of the roller beams. The
strand emerging out of an inclined plane thereby tends to lead downward
and forward, at an angle (Fig. 4.1 (iii)). The vertical (Y) and horizontal (X)
displacement of guide eyelet center from the front roller nip, decides this
angle value. Since spinning is done in the vertical plane, the angle so formed
between front roller and the lappet guide by the yarn path with vertical
spinning axis is known as spinning angle (γ). As per spinning geometry it can
be evaluated as;
X
tan (γ) = [Eq. 4.1]
Y
Thus spinning angle can be varied by either changing horizontal
displacement (X) or vertical displacement (Y) of lappet guide. However,
its horizontal position cannot be altered, otherwise disturbs centering with
spindle (Fig. 4.1 (v)). On the other hand, vertical displacement is continuously
changing during bobbin build up due to traversing and advancement performed
by thread guide rail.
• Farther the lappet guide to front roller [larger X], spinning angle (γ)
formed will be small. But it acts more as twist barrier due to increased
angle of contact at lapper guide. Thereby twist flow stops earlier and
forms larger spinning triangle. Presence of longer twist less band or
longer weak band, increases chances of end breaks.
• Closer the lappet guide set to front roller [smaller X], spinning
angle (γ) formed will be large. But it acts less as twist barrier due to
reduced angle of contact formed at lapper guide. Thereby twist flow
moves closer to front roller nip and forms smaller spinning triangle,
represents smaller twist less or weak band. Thereby chances of end
breaks due to low strength get reduced at this end. However, higher
deflection of edge fibers increases stress on edge fibers to get bind
with core and either protrude them out, or increases fly generation.
Thus value of spinning angle (γ) must be retained within desired limits for
controlled yarn quality and spinning stability. It is ranging between 17 and 35
degrees according to spinning geometry of modern ring frame.
Thus the contribution of lappet guide in ring spinning can be summarized
as:
i. The thread guide is acting as guide during changeover of the plane,
viz., inclined drafting plane to vertical spinning plane.
ii. Its vertical position with respect to front roller defines spinning angle
(γ), angle of wrap at front roller and also spinning triangle. Correct
selection of these parameters facilitates easy flow of twist without
any obstruction right up to the nip of front roller.
iii. Vertical distance of lappet guide from ring defines balloon height.
Balloon height has a major share in defining spinning tension as well
as spinning stability.
iv. Its alignment with spindle controls symmetry of balloon. Any

deviation in its setting is thereby liable to form asymmetric balloon
formation, and thereby end break.
4.3.2 Anti-ballooning device

Yarn length projecting down from the thread guide to ring–traveller remains
unsupported. Traveller revolves this bottom end of yarn at high speed for the
insertion of desired twist at the given delivery speed of front roller. The high
speed rotation generates centrifugal force and causes the yarn to swing away
from the bobbin. The result of this is a whirling outline of the yarn known as
balloon. Bigger the size (height and diameter) of the balloon formed, more
will be the stress undergone by the yarn forming the balloon. However ring
spinning is always carried out under tension as; fiber orientation in yarn matrix
gets improved under tension and contributes positively in yarn strength.
Hence bobbin is encapsulated within whirling outline of the yarn
spinning. So, balloon should be large enough to remain clear of the bobbin
but it should not be too large otherwise results in multiple end break due to
balloon slashing. This demands strand of fiber forming the balloon must not
be slack. But if this tension exceeds the yarn strength results in ends down,
adversely affecting spinning stability and yarn quality. As yarn tension during
twisting is mainly influenced by the dimension of the balloon, viz. height and
diameter, they need to be controlled. Anti-ballooning devices like separators
and balloon control rings are used for the purpose between thread guide and
ring (Fig. 4.2).
Figure 4.2 Anti ballooning device

4.3.2.1 Separators
If too wide balloon forms during spinning, causes slashing of the balloons
and results in multiple end break as mentioned above. Slashing of balloon
refers striking of adjacent balloons with each other. This is totally undesirable
phenomenon for ring spinning as it increases downtime of the machine as well
as hard waste. So, it becomes necessary that yarn balloon diameter (D) must
be controlled within limits. Separators are provided for this purpose between
two neighbouring spindles (Figs. 4.2 (i–ii)). As the name suggests it keeps
adjacent balloon separate from each other.
Separator is a thin metal plate, of different shapes, rectangular, oval etc.
It is used to prevent balloon slashing, so, always located halfway between
adjacent spindles above the ring rail. They were made up of thin sheet steel
plate with large slits punched on it to reduce the weight on old ring frames.
But nowadays it is made up of light weight sheet aluminum or plastic without
any need of punching. The surface of the separator is made highly smooth to
prevent yarn damage on striking with this surface.
These separators are operated by a separator bar (lifter rod) supported
by a bracket on the ring rail. This bracket can be adjusted to vary the travel.
Separators are readily tipped back for doffing, and a guard attached to the
roller beam knocks them back into position if the frame is started while they
are tipped back.
Automatic type separators are the fixed type of separators. This type, as
illustrated in Fig. 4.2(iv), is attached to the ring rail by means of a bracket.
They can be tipped back in the same manner as the type above described. This
style is always in a constant position relative to the ring rail.
Although separators are designed to control balloon geometry and thereby
spinning tension, they possess some inherent disadvantages. They are:
i. The yarn forming the larger balloon gets strike with the metallic
separator. It can prevent undesirable striking between adjacent yarns
but beating against the surface itself is disadvantageous. It gives rise
to napping of the thread, formulation of fly and molten spot formation
for the manmade due to abrasion.
ii. Doffing becomes difficult, as separators are located in the way to doff
the bobbins from the spindle. So, they need to be tipped back from the
bobbin withdrawal path.
• If they have swing back at the time of doffing need to swing
forward into the proper running position as the frame makes
the first traverse after doffing.
• Also it becomes compulsory to mount separator blades in

sections on respective lifter bar. All together increase labour
compliments involved in the work.
4.3.2.2 Balloon Control Ring (BCR)

Balloon height (H) must be large enough to prevent the interference to
encapsulated rotating bobbin. But too high balloon can exceeds yarn strength
and gives rise frequent end down. Apart from that freely rotating length of
yarn during twisting follows the theory of vibrating string. Accordingly height
of the balloon should be maintained lesser than the length of node. Otherwise
yarn will interfere with rotating bobbin at cross over point (end of node),
results in balloon collapse. Thus balloon height must be retained to the level
desired for stable spinning; without node formation as well as not too less.
Balloon control ring is designed for the purpose.
Balloon control ring is the smooth rounded aluminum alloy ring placed
in between thread guide and ring (Fig. 4.2 (iii)). It restricts the balloon in
the middle in such a way that two smaller balloons formed, which are in
themselves stable. However, balloon height is continuously changing with
ring rail traverse. So, to get equal balloon halves throughout doff, all the
balloon control rings are mounted on the lifter bar and capable of traversing
in synchronization with the ring rail.
Balloon checking rings permit operation at higher speeds with longer lift
bobbins, but can result in:
• Napping of the thread,
• Severe fiber abrasion (formation of fly) and
• Formation of melt points on manmade fibers, as the thread rubs
against them.
Thereby close attention must be paid to the yarn damage caused by them.
Analytical approach of “Balloon theory” must be used in making up scientific
decision.
4.3.3 Spinning ring

The technique used for the production of spun yarn from the drafted strand
of staple fibers has given the name from the ring. However, ring–traveller
combination is used for imparting turns of twist for binding the parallel strand
of fibers. Both the twisting elements have their own importance.
The spinning ring is a part followed next to the thread guide in the twisting
mechanism. It serves as a track for revolving traveller during twisting. The
position of traveller on ring with respect to encapsulated bobbin defines the
winding position of the yarn. The angular and vertical winding positions
are altered by the relative displacement of traveller on the ring and ring rail
position respectively. Ring rail is the movable support frame for rings. It
traverses up and down to guide the yarn onto different parts of the bobbin, to
get desired pattern of bobbin build up.
4.3.3.1 Ring design

As per the name suggests, ring is a narrow, vertical, cylindrical steel band. It
is provided with a horizontal flat arms, which projects at right angle from both
the sides of the top edge (Fig. 4.3 (i)).
Figure 4.3 Spinning rings
The vertical height (b), formed below the horizontal top part is known as
“web”. This web is quite thin enough to allow free friction less rotations to the
traveller, although its ends may be close together, but still clear the web. Web
thicknesses (t) ranges normally around 0.8–0.85 mm.
The horizontal top part of the ring is referred as “flange”. It should be
broad enough to prevent lifting away of the revolving traveller from the
web. But at the same time it should not too wide to make traveller mounting
difficult. Thus one of the criteria considered in the selection of right traveller
is its compatibility in fitting on the ring flange on which it runs.
4.3.3.2 Classification of ring
There are different ways to make distinction for types of spinning ring. They
are briefly mentioned below:
(A) Based on upper cross-sectional shape

Rings can be classified normally based on its upper cross-sectional shape, e.g.
‘T- shape rings’ and ‘I- shape rings’.
T-shape rings: The rings with only one top serving track for traveller
(flange) are known as single flange rings. Their upper cross- section shape is
matching with letter ‘T’, so classified as T-shape ring.
There are further two categories considered under this type: (i) Common
ring and (ii) Plain ring (Fig. 4.3 (ii)).
i. Common ring: It is the single flange ring, where the flange and web
are the upper part of a heavy cylindrical ring. The bottom part the
ring, below the web, flares to a great enough diameter outside the ring
to give a shoulder to fit against the top of the ring rail, while the lower
part of the ring fits into the hole of the ring rail. One or two screws,
in the front of the rail may be turned against the lower part of the ring
and secure it firmly right in a place.
ii. Plain ring: The top part of this category is similar to the common
ring, made up of flange and web. But the bottom part is just a short
extension of the web which is inclined slightly outward to fit into
some form of ring holder.
I-shape rings: The rings with two serving tracks for traveller
(flanges), one at top and another at bottom are known as double
flange rings. Their upper cross- section shape is matching with letter
‘I’, so classified as I-shape ring (Fig. 4.3 (ii)). Since top and bottom
ends are duplicates, the either can be used for the traveller, so also
called ‘Double adjustable rings’ or ‘Reversible rings’. The one at the
top is used for the track and the other one fits into the holder. After
years of service, one side up, these rings may be thoroughly cleaned
and polished and will give years of additional service when reversed.
However, it often transpired that the underside of double flanged ring,
which has been unused to that point and served as a mounting, has
become unserviceable due to corrosion, etc. These rings are therefore
now hardly used.
(B) Based on lubrication arrangement
Rings of above two basic categories can be further classified as ‘self-
lubricating rings’ and ‘non-lubricating rings’.
Self-lubrication rings: They are provided with added compartment below
the web. It is filled with the lubricating oil, which continuously lubricating
traveller ends (legs) via wick action to reduce friction between them. Normally
these types of rings are used for heavy travellers, involving higher traveller-
ring surface friction, e.g. on Ring doublers or on worsted ring spinning.
Non-lubrication rings: There is no provision for continuous lubrication

between ring and traveller. All the rings, irrespective of single flange or double
flange, used for cotton spinning are of non-lubricating type.
(C) Based on production pattern

Production pattern point of view in broader sense rings can be of two
categories; Conventional rings and Modern rings. Conventional rings can
be single flange rings or double flange rings as mentioned earlier. They can
be further subdivided into different groups based on their structural features
(Fig. 4.4) mainly as follows;
Figure 4.4 Types of conventional spinning rings
(D) Based on structural features of conventional single flanged rings

(i) Based on diameter measure:
• Reduced rings: The diameter of the ring is reduced than the diameter
of its bottom portion. The lower part has the diameter equal to the
recess in the ring holder. They can be used on the machines originally
designed for larger diameter rings.
• Enlarged rings: The diameter of the ring is increased than the
diameter of its bottom portion. The lower part has the diameter equal
to the recess in the ring holder. They can be used on the machines
originally designed for smaller diameter rings.
(ii) Based on web shape:
• Curved web rings: These rings have curved inside web rather than
perfectly vertical web. This helps in reducing the traveller friction
on the outside of the web, especially in the event of backtracking.
Normally preferred for the travellers having larger circle, as they are
more prone for tilting.
• Ribbed web rings: These rings have a rib around the center of the
web, sometimes on the inside and at the other times on both inside as
well as outside. This adds to the surface are of the ring for the ease of
heat dissipation.
However, all the modern rings are single flange type with marginal
changes in their structure to deal with high speed spinning.
4.3.3.3 Ring size

The ring is designated based on the measure of its diameter, flange width and
web height.
Ring diameter: It is the distance across the ring inside the flanges. The
ring diameter ranges from 34 mm to 76 mm. Small diameter rings are used
for fine yarns and for weft in case of conventional direct weft system (now
obsolete), where package size is limited by shuttle size. Larger rings are used
for coarser yarns and longer lift packages.
Flange width: It is a horizontal measure of overall flange width. It is
represented as “Ring Flange Number”. The ring flange number is based on a
width measured in the unit of 1/32 of an inch [old]. Accordingly, the flange
width of 3/32 of an inch, called “number 0 flange”. For each increment of
thirty-second of an inch change, the number is increased by one.
Flange sizes are standardized for its ‘mm’ measure in terms of flange
number for new concept of ring flange numbering. Table 4.1shows this
relationship.
Table 4.1 Ring Flange Numbering Systems
Flange No. 1 1.5 2
Flange width (F, inch) 4/32 4.5/32 5/32
Flange width (F, mm) 3.2 3.7 4.1
Flange width can be measured in mm or inch with any ruler or caliper.

Using the standardized size table the measured value can be converted to
equivalent ring flange number. Small steel plate gauges are also available.
They have different size notches, engraved with due numbering to read off
ring flange number directly (Fig. 4.3 (iii)).
Flange width selection is influenced by the weight of the traveller.
Traveller weight is less for the finer count and more for the coarser one.
Thereby ring flange width is not possible to be standardized. Otherwise the
traveller for finer count on rings with medium or wide width flange would
have to be made from such a finer wire that it would quickly wear or spring
off the ring. On the other, if coarser yarns should be spun on narrow flange
rings, the traveller should be made of heavy gauge broad wire. Such traveller
would be difficult to manage on narrow flange ring. Consequently, in general,
narrow width rings are used for finer yarn and wider flanges for medium and
coarse yarns.
Height of ring: Different manufacturers have slightly different base
dimensions and tolerances for the rings. Although the rings have identical
diameter and flange width, they do not fit properly in a given ring holder. So,
mention of ring height is necessary along with diameter and flange width for
its true identification.
The height of ring generally ranges from 0.3125 mm (old) to 0.3750
mm (new). The height adds to the area available for the heat dissipation. So,
modern ring frames operating with higher speed, liable to generate more heat
due to friction, are normally provided with rings with more height.
4.3.3.4 Manufacturing of ring

Manufacturing process of ring is mainly based on the ring characteristics
required for getting desired performance. A good ring in operation should
have the following features:
• Homogeneous raw material
• High wear resistance for longer operating life
• The ring should be tough and hard on its exterior. The running surface
must have high and even hardness in the range 800–850 Vickers.
• The traveller hardness should be lower (650–700 Vickers) than the
ring. Thereby wear occurs mainly on the traveller, which is cheaper
and easier to replace.
• Surface smoothness should be high, for least friction with traveller.
But it should not be too high, otherwise lubricating film* cannot build
up.
• It should have exact roundness to match with the profile of the
traveller.
• It should have an even surface free of spots to prevent obstruction to
traveller movement.
• Correct relationship between ring and bobbin tube diameters as per
spinning geometry.
• Mounted on ring rail in perfectly horizontal position and exactly
centered relative to the spindle.
*Lubricating film: It refers thin film builds up of cellulose and wax. This
material arises from material abraded from the fibers. If fiber particles are
caught between the ring and traveller, then at high traveller speeds and with
correspondingly high centrifugal forces, the particles are partially ground to
a paste of small, colourless, transparent and extremely thin platelets. These
platelets are continually deposited on the running surface of the ring, offering
smooth surface to revolving traveller and reduces friction between them.
Thereby it is known as lubricating film. These platelets are also replaced
continuously during working.
The position, form and structure of lubricating film depends on
• Yarn fineness
• Yarn structure
• Fiber raw material
• Traveller mass
• Traveller speed
• Height of traveller bow
Material: Rings are made up of a case hardened high grade steel alloy.
Owing to their higher hardness, traveller change frequency was too high
on modern high speed ring frames. Modern rings usually feature a surface
coating. The object of such coatings is mainly to reduce friction and wear.
Addition to this it also prevents corrosion and simplifies running-in the ring.
Coatings used include:
• Oxides
• Nitriding
• Carbonitriding
• Hard chrome
• Nickel (in some cases containing hard particles)
• Ceramics
The currently customary ring material is Carbon-Nitride coated
(Carbonitriding) high grade steel alloy.
Manufacturing process:
It includes following steps:
(a) Machining: Seamless tubes with desired height are prepared out of
the selected raw material as per manufacturer’s need. They have
given desired inner and outer shape and profile on special lathes with
the help of different tools.
(b) Hardening: It is carries out either by: (i) through and through
hardening (old); or (ii) case hardening process (new).
(c) Polishing: This makes the ring smooth. Special machines hold and
revolve the rings and fine abrasive (powder or paper) abrade them.
A coolant liquid may be optionally used. Without coolant, the ring
may lose hardness at high temperatures generated in the course.
The finishes may be (i) Matt or Satin finish (micro etching) and (ii)
Chemical or Electrochemical polishing (Rough and dull effect). A
black film of iron oxide having 0.0127 mm thickness is applied in
chemical process. Whereas metal is removed from the surface before
application of film in electrochemical process.
(d) Inspection: Rings are thoroughly checked for uniformity of hardness,
surface, ovality and cracks.
4.3.3.5 Mounting of rings
Rings, so manufactured are mounted on a ring rail. The ring rail is a cast iron
(old) or steel (new), long, narrow, channel-shaped metal plate, the length of
one side of the ring frame. It is bored with holes at regular intervals to match
with the spindle gauge. These holes are concentric with the spindle and are
large enough to accommodate spinning rings or ring holders. The rail is held
in a horizontal plane keeping the flat side upward. The rings are mounted in
these holes by one of the following methods:
(a) Direct mounting: Common rings are directly mounted on ring rail.
They are essentially single flanged rings, with the lower portion
extended long enough to pass through the hole on the ring rail. The
projecting edge of the ring, on its outside (Fig. 4.3 (ii)) and at the
middle of the web capable of supporting it at the top of the ring rail.
One or two screws are used to secure the ring right into the position
on ring rail.
(b) Indirect mounting: The rings other than the common rings do not
have the outward projection for the direct mounting. They have small
outward projection at the bottom end. This can help in securing them
on the holders (supports), fitted into the ring rail holes. They are
known as ring holders and of two types: (i) Cast iron ring holder and
(ii) Plate ring holder (Fig. 4.3 (iv)).
(i) Cast iron ring holder: The holder is made up of cast iron ring. It
is having outer bottom diameter turned down to the correct size
to fit freely into the holes of the ring rail. The inside diameter
of the holder is slightly larger than the size of the ring it holds.
The upper outside edge of the holder is rounded over and made
larger than hole. Thus the projected top edge supports the ring
holder fitted inside the hole from the top. The holder has a
radial cut on its one side. This provides spring type action to
hold the ring. The holder along with ring held inside is inserted
in the hole of the ring rail till the top projection sits on the rail.
One or two screws are inserted from the front end of the ring
rail to grip the holder firmly.
(ii) Plate ring holder: It is a sheet steel stamping; circular,
square or oval shape with rounded corners. It is not inserted
inside the hole but remains at the top face. It’s all outside
dimensions are thereby large enough to cover the hole of the
ring rail. The inside diameter of the holder is slightly bigger
than the outside ring diameter it holds. Two notches are
punched diametrically opposite edges to receive the screw,
which fasten the holder to the top of the ring rail. Two-three
small metal sections, known as lugs, spaced at equidistance
radially on the circle having the diameter smaller than the
bottom rounded edge of the ring. These lugs are designed to
hold firmly the lower portion of the ring. When necessary, the
rings may be pressed out easily, as the holder hole is larger
than the ring diameter.
Both the types of holders are also available with different inside diameter,
keeping outside diameter same. This can help in dealing with smaller size
rings on same ring rail. Sometimes sheet metal bushes are used to reduce
the inside diameter of the same holder for small diameter rings. This gives a
further cheaper option to deal with different size rings on the same machine
set up.
4.3.3.6 Running in of the ring

Whenever worn rings are replaced by new ones or new rings are mounted,
they lack a lubricant film. Purely metal/metal friction therefore prevails for a
certain length of time. So, the rings can very quickly be damaged by scoring
and pick-up. Ring manufacturers have therefore specified precise rules for
running- in, adapted to the given type of ring, after mounting the new ring on
the ring rail.
The running-in refers smoothening and passivation (oxidization) of the
rough surface of new ring by a schedule of traveller change and speed change.
Thus fiber lubrication, constant minimum mixed friction conditions and
minimum thermal stressing can be attained for the ring traveller. A careful
running-in process will improve the lifetime of the rings. Thus the running-in
procedure is decisive for the future positive / negative behaviour of the ring
and the length of its service life.
Every ring requires a certain degree of running-in time if it is to maintain

high traveller speeds with as little ring and traveller wear as possible. Important
points to be taken care off during running in schedule are:
i. Use steel travellers without surface treatment only. This can also
facilitate in easy identification of discoloration (blueing) of the
traveller at the end of running in cycle. After the termination of the
running-in process, steel travellers with surface treatment or nylon as
well as bronze travellers can be used.
ii. It is advisable to always change the traveller in the upper third part of
the cops. This can keep the stress on the traveller as low as possible
during the starting phase. These advantages are further extended with
the use of a traveller running-in program with reduction of the speed
by about 10% for 10 to 20 minutes.
iii. If any of the ends gets broken, mend it immediately. So, that all the
rings get equal running in time.
iv. Spindle speed should be reduced at least for the first 10 traveller
changes.
• If final speed is higher than 32 m/sec, reduce by at least 20%.
• If final speed is lower than 32 m/sec, reduce by at least 10%.
v. New rings should not be degreased, but only rubbed over with a dry
cloth.
vi. The running in should be done with the same traveller type which is
used for normal operation with the 10 to 20% less than normal speed.
It is not advisable to do running with the same speed but with 1 to 2
numbers lighter travellers than usual.
vii. The burnt traveller should not kept on ring for a long time, otherwise
damages ring surface.
Running in schedule:
i. Take traveller, 2 count lighter than normal and run the ring frame for
10 minutes at the speed < 30 m/sec. Then remove all the travellers
and clean all the rings with clean cotton.
ii. Take traveller, 1 count lighter than normal and run the ring frame for
30 minutes at the speed < 30 m/sec. Then remove all the travellers
and clean all the rings with clean cotton.
iii. Take correct set of traveller and run the ring frame for 60–90 minutes
at the speed < 30 m/sec. Then remove all the travellers and clean all
the rings with clean cotton.
iv. Take new correct set of traveller and run the ring frame for entire doff
at the speed < 30 m/sec. Then remove all the travellers and clean all
the rings with clean cotton. Check all the travellers for blueing of
travellers.
• If %burnt travellers < manufacturer’s recommended 15%, set
the spindles to normal speed and replacing travellers with new
correct set continue with regular spinning.
• But if %burnt travellers > 15% repeat 4th step until desired
level is achieved.
4.3.3.7 Modern high speed rings
The conventional T-shape rings were used along with C-shaped traveller.
Although this combination was offering pretty good yarn clearance, required
to avoid yarn hairiness, suffering from the major draw-backs associated with
traveller canting.
Traveller canting: The center of gravity of the traveller is usually above
the horizontal axis of the ring flange. So, the centrifugal forces caused on
ballooning make the upper and outer part of the traveller to tilt downward
to bring down the center of gravity of the traveller into a horizontal line of
the ring flange. This tilting causes the outer horn of the traveller to come in
contact with the outer surface of the ring web to prevent further tilting. This
phenomenon is referred as traveller canting, often said to be “back tracking”.
Extent of canting is in proportionate to traveller circle size. Frictional
contact of traveller horn with the ring web increases heat generation and thereby
limits allowable spindle speed. Thus interaction between ring and traveller
during running conditions imparts limitations to ring frame productivity. They
are overcome in modern high speed ring and traveller design features. The list
of rings used on modern ring frames is given below:
• Anti-wedge ring
• SU rings
• Orbit rings
• Sintered rings
• Rotating rings
Since ring–traveller works in combination the structural changes are
justified in interaction with respective traveller design in forthcoming section.
4.3.4 Traveller
Traveller is the hardened, tempered, scoured and polished piece of steel wire,
bent to get desired shape (C-shape, for conventional). This shape allows it
to fit loosely on the ring flange and races on its circular path by the yarn
pull. Rotations of traveller insert turns of twist to the drafted strand of fibers
emerging out of the front drafting roller nip.
Traveller does not have a drive on its own, but yarn drags it along the ring
periphery. However, traveller speed legs behind by the spindle speed. Traveller
and spindle together also help to wind the yarn on the bobbin. Traveller guides
the length wound up on the bobbin. The winding length corresponds to the
difference in peripheral speeds of the spindle and traveller. The difference in
speed should correspond to length delivered at the front rollers.
Hence its weight is too low in comparison to rest of the parts involved
in spinning, but reasonably high enough for yarn on which it rests. The force
generated by its weight on yarn during twisting determines balloon size
and thereby spinning stability. Even its weight determines winding tension
and thereby compactness of ring bobbin. Although seems very minute in
appearance, it plays a major role in success of spinning, viz.
• It imparts twist to the drafted strand.
• It guides the yarn for winding onto the cop.
• It defines spinning tension and winding tension.
A good traveller should possess following characteristics:

i. It should generate less heat.
ii. It should dissipate heat fast.
iii. It should have sufficient elasticity for easy insertion and to retain its
original shape after insertion.
iv. The friction between ring and traveller should be minimal.
v. It should have excellent wear resistance for longer life.
vi. Hardness of the traveller should be less than the ring.
4.3.4.1 Traveller design

There are many designs and sizes of travellers manufactured to deal with
varieties of material, size and types of yarns. The due alteration in the various
measures is done to get desired performance. The major features influencing
traveller selection and performance are illustrated in Fig. 4.5 (i–iii).
Arch/Bow: The curved top part of the traveller is known as “Arch” or
“Bow”. The arch can be high, medium or low. Its value is measured in terms
of Traveller circle.
Traveller Circle (Øc): It is a measure of the diameter of the inside of
the circular portion of the traveller. Different manufacturers designate it by
fractions, whole numbers, letters or combinations of these. Its value normally

ranges between 2.54 and 6.35 mm. Vertical height of the bow from the base
ends and yarn clearance are changing in proportion to the traveller circle. It
is customary thereby to use smaller circle traveller for finer yarn and larger
for coarser yarn. This can prevent undesirable rubbing of yarn with traveller
during spinning. Otherwise higher yarn abrasion at traveller contact surface
is liable to increase yarn hairiness, adversely affects yarn quality. However,
increase in traveller circle also moves its center of gravity (CG) away from the
ring flange, increases tendency of traveller canting.
Figure 4.5 Traveller design
The circle of the traveller must be large enough to readily clear off the
flange of ring on which it runs by giving enough room for yarn passage.
However, for any given weight of traveller, as the circle is larger, the wire
gauge used must be finer. The finer the traveller wire, the more quickly
traveller gets worn out. So, balance must be kept between traveller circle and
wire gauge used.
Centre of Gravity (CG): It is a point at which the total weight of traveller

gets concentrated. CG is always higher than CS due to lack of weight at flange.
The type of bow used determines the position of center of gravity. The lower
the bow of the traveller, the closer the center of gravity to the horizontal plane
of the ring flange during running of the traveller.
Centre of Symmetry (CS): A point equidistance from opposite edges
which serves as the center for the radius of traveller arch. It is the center
for the radius for the side curvatures as well as for the arch for the circular
traveller. It lowers down with the reduction in traveller circle value.
Horns: The bottom horizontal bent ends of steel wire facing each other
are known as horns. They help in fitting the traveller under flange of the ring,
close to the web and do not permit traveller to fly off the ring. The ends of the
horns are cut off straight (square point), or semi-circular (round point). This
provides smooth path of contact between traveller leg and junction point of
the inside of the web and the underside of the flange during running (Fig. 4.5
(ii)).
Flange: It is the gap between the ends of the horns. It helps in mounting
and retaining the traveller on the ring. This varies according to traveller number
and flange width of the ring. If the traveller flange is too narrow for the ring,
may break traveller at the point of mounting on the ring. If the traveller flange
is too wide for the ring, results in traveller fly.
4.3.4.2 Manufacturing of traveller

Travellers have to wind up very different yarns; coarse/fine, smooth/
rough, compact/bulky, strong/weak, natural fibers/manmade fibers, etc. It is
impossible to spin this diversity of yarns using only one type of traveller;
quite a wide range of travellers is required for this purpose. Differences in the
manufacturing process arise from raw material, additional treatment of the
material, shape, mass, wire profile and thread passage size (arc height). It is
up to the spinning mill operator to make a choice appropriate to his conditions
and requirements.
Material: Travellers are made up of different materials to deal with wide
varieties of material and yarn size to be spun. They are also given various
surface treatments to enhance the performance. Travellers are commonly
manufactured from a special soft steel wire. These are versatile in terms
of type of ring, material and count to be spun. The steel wire is rolled to
get desired cross sectional shape. Special machines are used for automatic
measuring wire length required for one traveller, cutting it and bent around to
get desired shape arbour. Frequent and regular inspection, at the machining
and before processing, assures the proper shape and weight of travellers.
These travellers are then carefully hardened and tempered, after which they
are scoured to remove rough edges and then polished. Final critical inspection
is done before packing and dispatch.
Other materials used are:
i. Brass alloy: It is used for wet doubling of cotton. These travellers must
be used along with lubricating rings only; otherwise ring–traveller
friction will be high due to transfer of brass on the ring surface.
ii. Nylon: Nylon travellers are widely used for spinning cotton, worsted,
woolen, man-made fibers, jute and glass. Due to its higher coefficient
of friction, they are made lighter to acquire desired yarn tension during
spinning. However, this adversely affects stability of traveller on the
ring during running. Spinning stronger materials like manmade fibers
or animal fibers wearing out of nylon will be faster due to higher
yarn–traveller abrasion. In such cases nylon traveller with metal
insert is used.
Additional treatment of the material: Selecting correct material for
the traveller amongst all, for qualitative and quantitative spinning is quite
important. It is based on the extent, the traveller can fulfill following
requirements:
• Generate as little heat as possible
• Quickly distribute the heat that is nevertheless generated from the site
where it occurs (contact surface) to the traveller as a whole
• Dissipate the heat quickly to the ring and the air
• Be elastic, so that the traveller can be pressed onto the ring without
breaking
• Display high wear resistance
• Have a slightly lower hardness than the ring, since the traveller must
wear rather than the ring.
Steel has found superior amongst all. Therefore travellers used in short
staple spinning are made almost exclusively of steel. However, pure steel does
not ideally fulfill the first three requirements. Traveller manufacturers have
therefore been attempting for decades to improve running conditions through
surface finishing. The various methods used for the purpose are:
(a) Electroplating, in which the traveller is coated with one or more
layers of metal, such as nickel, ceramic and silver, or
(b) Chemical treatment to change surface properties in order to reduce
friction and scoring.
(c) Diffused finishing treatment into traveller surface. The Bräcker
company has developed this process for introducing certain treatment
components into the traveller surface by diffusion and fixing them

there (sapphire traveller). This layer reduces heating and increases
wear resistance.
4.3.4.3 Traveller shape

It is important for thread passage. If this space is too small the thread rubs on
the ring, which results in napping of the thread, high production of fiber fly,
reduced quality and the formation of melt points in manmade fibers. The basic
requirements in defining proper traveller shape are:
Figure 4.6 Spinning travelle

i. The traveller must be shaped to match exactly with the ring in the
contact zone, so that a single contact surface, with the maximum
surface area is created between ring and traveller.
ii. The bow of the traveller should be as flat as possible, in order to keep
the center of gravity low and thereby improve smoothness of running.
However the flat bow must still leave adequate space for passage of
the yarn
The traveller shapes used in short staple spinning (Fig. 4.6 (i)) are:
(a) C shape travellers
(b) flat or oval travellers
(c) elliptical travellers
(d) N travellers and
(e) ORBIT travellers r
4.3.4.4 Traveller mass

It is given in terms of “traveller number” or “traveller count”. Traveller count
is a numerical designation of traveller based on the measure of traveller mass.
It represents the weight in grains of ten equal types of travellers. If the weight
of ten travellers is ten grains then traveller count is said to be one. As the
weight of ten travellers exceeds ten grains, the traveller count also becomes
larger. However, the increment is non uniform, on an average two grains per
number.
If the weight of ten equal type travellers is less than ten grains then
traveller is said to be ‘Ought traveller’ or ‘Nought traveller’, denoted by N/O.
Where, ‘N’ represents traveller number and ‘O’ indicates ought. The sizes
range from 1/0 (one ought) to around 25/0 (twenty five ought). These sizes
decreases in weight in a varying range of steps of 1 grain per number, ½ grain
per number and finally ¼ of a grain per number, until the finest commonly
used traveller size weighs about 1 grain per ten traveller.
ISO is the new numbering system and specifies the mass of 1,000
travellers in grams or traveller mass in milligram. Unfortunately; the sizing
of travellers has never been completely standardized. Each manufacturer has
its own system and when they are much alike, the ought traveller to vary
just enough so that it is not possible to work all makes into one rule. Most
of the manufacturer prints comparative tables showing the weights of other
commonly used travellers with theirs. This helps spinners in précised traveller
selection from differently sized system.
The mass of the traveller determines the degree of friction of the traveller
on the ring and thus the yarn tension. If the mass is too low, the balloon
becomes too large, the cop too soft and the amount of material taken up on
the cop too small. On the other hand, too high a mass results in high thread
tension and frequent ends down. The mass of the traveller must therefore be
adjusted exactly to the yarn count, tenacity and the spindle speed. If there is
a choice between two traveller weights, the heavier one is usually preferred,
since this results in higher cop weight, smoother running of the traveller and
better heat dissipation.
The traveller weights are determined beside the yarn number by material
being spun, yarn strength, spindle speed, yarn count and spindle speed. Their
relationship has been illustrated in Table 4.2.
Table 4.2 Relationship between Spinning parameters and Traveller count.
Fiber type Blends, synthetics 1-2 number heavier travellers

Yarn twist Low twist (Knitted yarn) Lighter travellers
High Twist (warp) Heavy traveller
Yarn Count Coarse Heavy traveller
Fine Light traveller
Spindle speed Higher RPM Rather lighter travellers
Spinning geometry
Small ring diameter Small balloon Lighter travellers
Large ring diameter Large balloon Heavier travellers
4.3.4.5 Wire profile

Different types of steel wire profiles are used in manufacturing traveller
(Fig. 4.6(iii)). Hence wire profile influences both; the behaviour of the
traveller and certain yarn characteristics, it should be chosen correctly for
spinning at maximum speed. The selection parameters for wire profile are
dependent on:
i. Traveller wire contact surface area with the ring. Higher the area of
contact, faster will be the heat dissipation. This helps in controlling
traveller temperature at higher running speeds and prevents it from
getting blue.
ii. Minimum frictional contact / friction between ring and traveller. This
can allow smooth running of traveller, with reduced thermal stress.
iii. Heat generation due to frictional contact between ring and traveller is
unavoidable fact of ring spinning. Apart from that high production rate
demands higher spindle speed. When the spindle speed is increased,
the friction work between ring and traveller increases as the 3rd
power of the spindle rpm. Consequently if the spindle speed is too

high, the traveller sustains thermal damage and fails. This situation
can be well avoided by good traveller by ease of thermal transfer. As
mentioned above higher contact surface distribute heat on larger area
and enhances thermal transfer.
iv. Yarn damage in terms of extent of roughening effect and yarn hairiness
introduced is attributed to available yarn clearance between ring and
traveller. Enough clearance, based on yarn size and type can reduce
yarn–traveller and yarn–ring friction, thereby controls yarn damage.
Based on the above phenomenon, wire profiles suggested by traveller
manufacturers for spinning different yarns are:
i. Flat (f) – It is a wider rectangular surface thereby provides good
sealing of ring. It is mainly used for medium cotton yarns.
ii. Speed (s) – It is flat but thicker rectangular profile. Being wider
provides good sealing of ring and heavier in weight, so used for
spinning coarser cotton yarn.
iii. Half-round profile (dr) – It gives good sealing and high speed with
reduced yarn –traveller friction and better sealing of ring. Normally
used for synthetic & blends.
iv. Half-round flat (udr) profile – This profile travellers offer wider
surface area and lighter in weight. It is therefore used for finer cotton
counts.
v. Flat and round (fr) profile – It offers reduced contact area with
increased gap for yarn passage. So, used for spinning synthetic, prone
to generate static charges.
vi. Half round (drh) profile – It is used for woolen and synthetic yarn. It
reduces static charge generation at higher spinning speed and offers
better heat dissipation due to higher cover area.
vii. Round (r) profile – It gives minimum traveller rubbing with yarn and
reduces yarn damage. It is used for heavy ear shaped traveller while
spinning coarser double yarn.
4.3.4.6 Special categories of traveller

The curved top part of the traveller is called the “arch”. It is designed to
provide enough clearance between ring and traveller for yarn passage, so that
yarn–traveller and yarn–ring friction can be minimized. Better yarn quality
can be realized due to reduced friction. The arch may be high, medium or
low. Circular (C-shape) travellers have high arch, normally used for spinning
coarser yarn owing to higher ring–traveller clearance. Standard travellers are
medium arch travellers. They are most commonly used travellers for short
staple spinning. The low arch travellers are often referred as “Elliptical
travellers”, as their rounded major part consists of an ellipse.
Manufacturers have done modifications to a given type of an arch to
meet fancied needs. These efforts have given special categories of travellers
(Fig. 4.7) as follows:
Figure 4.7 Special categories of travellers
(a) Double duty travellers: They are made by punching out a small
elongated oval hole in the center of the top of the arch. Normally
done for medium and heavy weight travellers. Elimination of metal
weight at the top of the arch lowers down center of gravity and brings
it nearer to the horizontal plane of the ring flange. Thereby minimizes
tendency of traveller canting and facilitates in reducing ring–traveller
friction. Apart from that it also helps in reducing lint collection on the
traveller. Different manufacturers have given different name to this
modification made, such as “Comet”, “Split Back”, “Imperial” and
“Perforated Bow”.
(b) Gravity travellers: Small quantities of steel have been ground away
from the side of the wire at the top of the arch. Commonly done for
fine travellers. This modification reduces traveller weight further
without affecting circle of traveller and wire gauge. This can facilitate
spinning without damage to yarn or traveller at high speed. Even

elimination of material from the top of the traveller brings center of
gravity closer to ring and minimizes traveller tilting tendency. Thus
better traveller running conditions can be attained.
(c) Gravity express travellers: Small quantities of steel have been ground
away from the full width of the top of the arch. Usually done for fine
travellers. This modification earns the same benefits mentioned for
gravity travellers.
(d) Bevel edge travellers: The steel wire has been rolled narrower at the
inside of the circle than the outside to acquire bevel shaped cross
section. Yarn is passing around this bevel edge, thereby not subjected
to sharp bend. As a result of this a smoother, cleaner yarn is produced
with minimum fly liberation during spinning.
(e) Oval wire travellers: Traveller wire is made flat on outside and half
round on the inside. Due to rounded oval shape edge, it offers minimum
resistance to yarn passing through ring and traveller. Prevention of
sharp bend at the exit end, similar to bevel edge produce good quality
yarn with minimum fly generation.
(f) Circle – D travellers: These travellers have low arch and elliptical
in shape. They have low center of gravity, required for good running
conditions of travellers during spinning.
4.3.4.7 Traveller speed

It represents the speed by which the traveller moves on the guiding track
(along ring flange), expressed in feet per second (old) or meter per second
(new). Usually this is a surface speed of traveller and not the rotary speed. The
surface speed is the product of ring circumference (feet or meter with traveller
revolutions per second.
\ Traveller speed = pDRNT m/sec [Eq. 4.2]
Traveller is negatively driven by the pull of the yarn and lags behind
the spindle speed as per winding revolution. Hence the lag is negligible per
second, traveller speed (NT) is replaced by spindle speed (Ns) for ease of
evaluation.
\ Traveller speed = pDRNs [Eq. 4.3]
Since traveller does not have a drive of its own, but is dragged along
behind by the spindle. High contact pressure (up to 35 N/ mm2) is generated
between the ring and the traveller during winding, mainly due to centrifugal
force. This pressure generates heat. If the traveller speed is raised beyond
normal levels, heat produced by the ring–traveller is around 350 to 400 degree
Celsius. This has to be dissipated in milliseconds by traveller into the air. But
low mass of the traveller does not permit dissipation of the generated heat in
the short time available.
If spindle (/traveller) speed is raised beyond normal levels, the thermal
stress limit of the traveller also get exceeded, a drastic change in the wear
behaviour of the ring and traveller ensues. The heat so developed soon burns
the traveller, makes it bluish and brittle. Such traveller will either fly off the
ring or breaks, results in end down. Excessive “end down” in spinning room,
makes work of operatives and waste control difficult. This adversely affects
quality of yarn produced and efficiency of spinning room.
Beyond the thermal stress limit of the traveller, adhesion forces between
ring and traveller get strongly increased, likely to cause welding between the
two. These seizures inflict massive damage not only to the traveller but to
the ring as well. The traveller temperature even reaches 400°C to 500°C and
the danger of the traveller annealing and failing is very great. All together
restricts the operating speed of the traveller and thereby spindle. Limitations
in increasing spindle speed results in reduced production rate of the spinning
department.
The maximum attainable speed of traveller without getting damaged
is known as “limiting speed of traveller”. It is 70 ft/sec. (22 m/sec) for
conventional set of ring–traveller and 145 ft/sec. (42 m/sec) for high speed
ring–traveller.
4.3.4.8 Traveller clearer

Yarn, which comprises a large number of more or less firmly integrated,
yet relatively short fibers, is fed through the ring traveller; it is inevitable
that fibers are detached. Most of them fly away from the traveller, but some
also often remain attached to the traveller. These can accumulate and even
form clumps. The resulting, excessively high mass of the traveller creates
high thread tension and ultimately leads to thread breaks. Fiber strippers, so-
called traveller clearers, are mounted near the rings (Fig. 4.6 (ii)) either on
ring holder or directly on ring rail, in order to prevent these accumulations of
fibers.
They should be positioned as close to the traveller as possible, but far
enough so that not able to interfere with the movement of the traveller.
Accumulated fly project outward due to its light weight under the influence
of centrifugal force and caught by traveller clearer placed nearby. Accurate
adjustment is thereby very important. Normally used setting is 0.5 mm [old]
and 0.2 mm to 0.3 mm [new]. Owing to their mode of operation they are
referred as mechanical traveller clearer.
4.3.4.9 Parameters influencing traveller selection

There is no scientific method (statistical or technical) prescribed till today
for the selection of the traveller for ring spinning. Hence number of variables
and their interactions involved in spinning are high enough, which renders
it difficult to derive such streamline process. The major detrimental factors
in traveller selection are yarn count, strength of yarn spun, surface speed of
traveller, condition of ring surface and angle of yarn pull.
Yarn count: It is a measure of linear density of yarn and for the given
i.
type of fibers varies with number of fibers per cross section. Coarser
yarn thereby possesses higher fibers per cross section and weight per
unit length (m). Such yarn during spinning bulge more at a given
spindle speed due to higher centrifugal force (F ∞ m). This can result
in multiple end break due to balloon slashing. A heavy traveller is
required to keep the balloon down to the proper size.
Yarn strength: Traveller is freely suspended on the yarn, thereby acting
ii.
as a tensioner during spinning as well as winding. If the traveller is
light, prevents end break but at the same time results in larger balloon
and soft package. So, traveller selected should be heavy enough to
bring down the balloon size reasonably, build up compact package.
However tension induced should not exceed yarn strength otherwise
causes end down at the same time. End break not only introduces
splicing or piecing fault to yarn, but also increases Bonda waste and
reduces machine efficiency.
iii. Surface speed of traveller: It varies in direct proportion of ring
circumference (diameter) and spindle speed. Centrifugal force (F ∞
n2) involved is higher while working with higher spindle speeds (n)
within the limiting speed of the traveller. Thereby to keep the balloon
of desirable size, heavier traveller is used.
Condition of ring surface: Smooth running of the traveller on the
iv.
track (ring) is quite important. Any obstruction coming on the way
due to poor surface characteristics, increases ring–traveller friction
gives faster traveller wear. Traveller change over cycle thereby
increases, adversely affects yarn cost due to added traveller cost and
reduced machine efficiency and production. It is desirable to maintain
ring surface smooth, polished and clean.
Hence spindle runs at a maximum practically attainable speed,
the traveller cannot be expected to last longer. At the same time
surface characteristics of ring also vanish fast. The tendency is more
pronounce with the use of heavy traveller. So, running-in cycles for
the ring must be planned accordingly for retaining desirable ring
surface characteristics.
Angle of pull: It is an angle (Ø) formed between tangent drawn to
iv.
yarn path from traveller to bobbin and line passing from traveller to
bobbin axis, also known as “winding on angle”.
Figure 4.8 Angle of pull
The angle of yarn pull decides the magnitude of forces acting on traveller
(Fig. 4.8). Yarn has been led through traveller to the bobbin for winding.
Bobbin is mounted on the spindle and driven positively. It pulls the yarn from
the front drafting roller nip by winding force (F) at an angle (Ø). The axial
component (F Cos Ø) keeps traveller pressed against the ring, not allow it to
fly off the ring against the balloon force. The tangential component (F Sin Ø)
lifts traveller against the ring and rotate around the ring. Thus yarn tension
at the point of winding dependent on the tangential component of winding
force. Hence Sin Ø = r/R, for the given ring diameter (R), it depends mainly
on bobbin radius (r) or bobbin diameter. In the beginning of doff (Fig. 4.8
(ii)), yarn is wound on the smallest bobbin diameter (re) results in smallest
value of ” but highest value of “Cos Ø1 ” component. Thereby, yarn has to
work more to rotate the traveller around the ring. This increases yarn tension
and end down frequency. Whereas at the end of the doff, winding takes place
on full bobbin having highest radius (rf) value, thereby highest angle of pull
“Ø2”. This reduces axial component quite considerably but build up higher
tangential component of pulling force. Thus, yarn has to work less to rotate
traveller, reduces yarn tension.
The yarn tension is reasonably high with a small angle of pull, likely to
cause end breaks. If yarn is not strong enough to sustain the stress, end breaks
will be frequent and adversely affect spinning stability. The situation is more
crucial with the use of larger diameter ring and smaller bare bobbin diameter.
So, good commercial spinning conditions demand the minimum angle of pull
to be kept 23 degrees. Satisfactory spinning conditions can be attained while
working with an angle of pull ranging between 23 to 35 degrees.
Technological guidelines for the traveller selection
(a) When the ring diameter is less, balloon diameter will be small. This
leads to more yarn tension. Hence use lighter travellers.
(b) When the ring diameter is bigger, balloon diameter will be more.
This leads to less yarn tension and the balloon touches the separator.
Hence use heavier travellers.
(c) When the tube length is short, the yarn tension will be more. Hence
use lighter travellers.
(d) When the tube length is long, the yarn tension will be less, hence use
heavier travellers.
(e) When the yarn contact area and ring contact area in traveller is closer,
fiber lubrication is better, especially in cotton. For this use heavier
travellers.
(f) When spindle speed is increased use lighter traveller with low bow
height. At higher speeds, lighter travellers give lesser yarn tension.
When low bow height travellers are used center of gravity will be
closest to the ring which aids in running of traveller.
(g) Use lighter travellers on new rings. This is done to reduce end
breakages by reducing the yarn tension.
(h) Use heavier travellers on old rings. This is done to avoid bigger
balloons.
(i) Heavier travellers reduce hairiness.
(j) When using lighter travellers, yarn stretch will be less. It helps for
better yarn elongation.

(k) During running-in the end breakage rate should be kept minimum,
hence use lighter travellers.
(l) The shorter the balloon, the lighter the traveller to be used, the higher
traveller speeds can be achieved.
4.3.4.10 Requirements for smooth traveller running

The smooth well-in-track running of traveller on the ring is the most important
factor in determining the qualitative and quantitative performance of ring
spinning. The desired running condition of traveller requires:
i. The rings should be correctly centered with regard to the spindles.
ii. The yarn guide eyelet should be well centered with regard to the
spindle.
iii. The spindle bearing should be in good condition, thus preventing
spindle vibrations.
iv. The ratio between bobbin diameter and ring diameter should be
correct.
v. The concentricity of the balloon control ring with regard to the spindle
should be correct.
vi. The fiber tufts which accumulate on flange travellers should be
removed by means of suitable traveller cleaners.
vii. The climatic conditions (temperature and relative air humidity)
should be favourable for the spinning process.
viii. The air in the mill should be free from disturbing particles that
influence efficient performance of the traveler.
4.3.5 Engineering high speed ring–traveller

Productivity of the ring spinning is limited by yarn stress caused by many
variables. The major influencing are balloon tension, danger of yarn damage
due to the guiding element coming in the way and traveller limiting speed
defined by the traveller in interdependence with the ring, and yarn. However,
in most cases, this limit arises from the maximum ability of the ring–traveller
system to withstand occurring stress situation during operation. So, both the
participating frictional bodies during spinning should be treated together
instead of independent one for evaluating practical significance.
Working under optimal running conditions, traveller wear does not only
depend on traveller material but also on the problems of heat dissipation.
The heat generated between ring and traveller must be reduced as quickly
as possible to avoid local temperature in the traveller wear zones. Thereby

all improvements of rings and travellers design aimed with minimum heat
generation but maximum heat dissipation. Thermal loading (L) of traveller
F cos Ø
depends on surface pressure P = acting between ring and traveller.
A
Where, A is the contact surface area between ring and traveller and “Ø” is
the angle of pull. Thus thermal loading (L) increases with reduction in ring–
traveller surface contact area (A). The various stages of technological changes
in the engineering design of ring–traveller are evaluated in these regards in the
forthcoming discussion.
Conventional ring–traveller: Symmetrical polished cast iron T-ring and
C-shape steel traveller were used on conventional slow speed ring frame
(Fig. 4.9 (i)). Owing to bigger circle of traveller, offers higher yarn clearance.
Thereby reduces traveller–yarn and ring–yarn friction, likely to result in less
yarn damage. However, its higher center of gravity causes traveller tilting
or traveller canting. It makes traveller to make only two point contact with
the ring. Thus with very small contact surface area ‘A’, thermal loading of
traveller is high. Temperature rises up to 320°C at points of contact. Due to
smaller surface contact area, this heat is not dissipated fast in a short time
(millisecond), limits traveller speed to 22 m/sec only. Allowable spindle speed
(Ns = 7, 785 rpm) and thereby production of ring frame is less, as explained
below.
Traveller speed = pDRNs m/sec [Eq. 4.4]
Where DR = Diameter of ring for conventional ring frame = 54 mm
54
\ 22 m/sec ×60 = p × × NS
1000
\ Ns = 7,785 rpm
Production rate is further restricted by the metallurgical limitations of
ring–traveller. Higher coefficient of friction (µ) prevailing between them,
increases undesirable heat generation. Higher heat generation along with poor
rate of heat dissipation does not permit the spindle to operate at higher speeds,
as µ ∞ Ns3.
Asymmetrical ring – elliptical traveller: Elliptical travellers have been
developed to meet with the high production demands by breaking the barriers
of traveller speed. Elliptical traveller has low center of gravity, closer to center
of symmetry due to its low arch. This reduces tendency of traveller canting
during running, prevents only two point contact between ring–traveller.
However, if the T-shape ring flange shape is retained with elliptical
traveller it becomes virtually impossible to increase surface contact area.
So, anti-wedge ring has been designed. It has ring flange with a flared inside
surface and is flattened off considerably on top. This change in shape enabled
a ring–traveller with a low center of gravity, precisely adjusted arc for smooth
yarn passage and increased contact area during running (Fig. 4.9 (ii)). Thus
the combination provides greater bearing surface for the traveller and helps in
rapid heat dissipation by spreading the heat over a wider area. This can permit
the traveller to run faster up to 30 m/sec without getting over heated.
Figure 4.9 Developments in the design features of ring-traveller
Application of surface finish has also reduced coefficient of friction

(µ) and permitted spindles to operate at higher speed. Improved surface
characteristics of ring–traveller and uniform wear of traveller and ring due
to wider bearing surface has also enhanced their shelf-life. This has reduced
down time required for traveller change as well as ring running-in. Also labour
compliment involved in this course get reduced, thus added to the economy.
Hence the height and width of the elliptical traveller is less, thicker cross
section wire is used for a given traveller mass. Such traveller will not wear out
faster and advantageous so far as the life of traveller is concern.
Anti-wedge rings and elliptical travellers belong together and should only
be used in combination. Since the space for the yarn passage is limited, this
combination can only be used for fine and medium count yarns.
Cropped anti-wedge ring – flat traveller: It is basically anti-wedge ring
only, but its flattened top surface is cropped by an angle ‘θ’ (Fig. 4.9 (iii)).
Such that θ = 0.5°. This resulted in a large clearance for coarser yarn passage.
This combination retains all the advantages associated with anti-wedge ring-
elliptical traveller.
The arc of the traveller could also be flattened off further, to make use of
oval traveller/flat traveller with such ring for spinning finer counts. Further
lowered center of gravity permits better running condition for the traveller, fit
like clip on the ring.
Inclined/oblique ring: Ring flange has been made inclined instead of flat
horizontal one to increase the surface contact area between ring and traveller.
This type of ring was first invented in Russia and marketed as the “SU ring”
in 1960.
Figure 4.10 Orbit ring and traveller
SU-Ring: The outstanding advantage of inclined-flange rings is the

much larger contact area (A), almost 4 to 5 times; between ring and traveller
compared to CR anti-wedge ring–traveller rings (Fig. 4.9 (iv)). Thereby
expectedly it should reduce the pressure (P) between ring and traveller
considerably and thus improves heat dissipation from the contact area. Beside
their bigger contact area oblique flange ring–traveller has another advantage
as well. For the identical yarn tension, i.e. same frictional forces, 10–15%
lighter travellers can be employed for SU rings in comparison to T-flange
rings. The loading of ring–traveller can be further reduced thereby results in
higher speed potential of the traveller up to 15%. The use of lighter traveller
for oblique ring can be well explained from the geometry of the forces
(Fig. 4.10 (i)). In the steady state of traveller, the forces centrifugal force
(Z), yarn tension (S) and normal force between ring and traveller (N) acting
on it in the plane through the spindle axis forms a closed triangle of forces.
This triangle of forces is of general validity for the given balloon conditions,
irrespective of ring–traveller system employed. With T-shape ring there is a
single normal force FN (Fig. 4.10 (ii)), between ring and traveller. However
it has been divided into two components N1 and N2. Vector wise the sum of
N1 and N2 is equal to normal force N; that is N = N1 + N2. But scalar wise it
exceeds N, that is; N < N1 + N2. Hence the frictional forces caused by the
normal forces: µN < µN1 + µN2 or R < R1 + R2.
Thus under the same working conditions, i.e. traveller mass and
coefficient of friction, oblique ring offers higher frictional force on the
traveller. Consequently for the same yarn tension, lighter travel should be
used with oblique ring–traveller as compared to T-ring–traveller.
Summarizing the discussion, with oblique ring–traveller two major
advantages can be earned:
• Significantly bigger contact surface area between ring–traveller, and
• Use of lighter weight traveller.
Yet this system has not found commercial success despite of its advantages.
That is mainly attributed to its following limitations:
i. Surface contact area (A1) between straight profile of the ring and
traveller available for absorbing force N1 is indeed large enough. But
the surface contact area (A2) available at the top rounded edge of
the ring is very small for absorbing force N2. As a result the surface
N2
pressure (P2 = A ) in the range of force N2 is much higher than
2
N1
surface pressure (P1 = A ) in the range of force N1. Although surface
1
pressure P1 is much lesser than T-ring, surface pressure P2 is too

high. Consequently attainable traveller speed gets limited by higher
pressure P2, even lower than T-ring.
ii. Owing to the different cross sectional shape, total wire length required
for SU-ring traveller is significantly higher than C-shape traveller
used for T-ring. This makes it necessary to use fine gauge wire to
retain same traveller weight. This difference in wire gauge is further

magnified by the peculiarity of the oblique ring mentioned earlier.
The situation becomes worse for spinning fine count. As there is a
limitation in terms of wire gauge, i.e. how thin the wire can be used
for making required lighter traveler.
iii. There is always a danger of unthreading on the inside of the ring at
the stop-start operations on ring frame due to snarling tendency of
twisted yarn with SU-ring. This property is manifested in varying
degrees depending on yarn and fiber type. Nevertheless, it has resulted
in many cases in severe increase in the frequency of end down at the
point of restart. Thus the use of SU-ring becomes impossible.
Thus oblique/inclined ring concept, although sound impressive, was not
become successful in the market in the form of SU-ring.
Orbit ring–traveller: Rieter took up SU-ring design and developed
it to perfection in the late nineteen-eighties. The corresponding ring was
launched on the market under the ORBIT brand name in 1991. This work was
performed in close collaboration with Bracker A. G., Pfaffikon and Prosino
S.R.L., Borgosasia. By dint of this cooperation between ring frame machine
manufacturer and ring–traveller manufacturer, the desired target was achieved
successfully. The changes done in the basic design features of SU-ring to
overcome its limitations are summarized below:
Reducing surface pressure at the top of the ring: The division of the
1.
normal force N into two components N1 and N2 mainly dependent
on the inclination of curved surface. So, the collar has been inclined
at an angle “γ” (Fig. 4.10 (i)). This has allowed increased surface
area contact at top (A2) and thereby reduced traveller thermal loading
N2
(P2 = A ). Even inclination angle “γ” was optimized by systematic
2
research done by Rieter. This has not only reduced wearing out of rings
at top but also minimized traveller’s thermal loading significantly.
Spinnability of fine yarns: Spinning fine yarns with inclined rings
2.
successfully became indeed difficult in case of SU-ring due to use
of longer wire length as compared to C-shape traveller. So, SU-ring
profile needs to be modified in order to reduce required wire length.
The collar height of SU-ring was reduced substantially to shorten
both the legs of traveller used for it considerably (Fig. 4.10 (ii)). As
a result orbit ring traveller length is negligibly longer than C-shape
traveller for T-ring with 3.2 mm flange width (used for fine counts).
This has enabled orbit rings to spin comfortably finer counts.
Preventing unthreading: SU-ring inner leg is straight and open to

3.
bottom. Torque present in twisted yarn causes the yarn to slip out
of the traveller at the toe of inside leg in the event of stop–start of
machine. Rieter has given a provision of supporting ring. It collects
the thread and facilitates rethreading on restart. Thus rules out
rethreading and with it the bugbear of virtually all of the end breaks
at the stop–start of the machine. This supporting ring has revealed
a secondary benefit as well. Comparative trails with and without
it show that the load bearing fiber lubricating film in the zone of
conical surface is noticeably increased by the use of supporting
ring.
Optimizing ring surface: The surface pressure with orbit ring–
4.
traveller is considerably less than the conventional set of ring–
traveller. The best results can be further realized by optimizing
surface characteristics of friction partners. Improved metallurgy
(titan rings) and finish seizes resistance on the ring surface. Longer
life span reduces ring change frequency perceptibly and thereby
downtime due to Running-in. Furthermore characteristic colouring
of the orbit ring–traveller assists in easy location of traveller when
manually clearing end breaks.
Enlarging yarn passage: Ring surface diminishes strongly from
5.
the top of the ring towards the outside. This increases the gap for
yarn passage and thereby reduces friction involved. The traveller-
yarn friction is further reduced by the changed location of the force
application point on the orbit traveller. This has made the angle of pull
(Ø) on this traveller only half as wide as on a conventional traveller.
Thus reduces fear of yarn damage/melting, especially when spinning
fibers susceptible to damage.
Increased limiting speed of traveller: Traveller wear is dependent
6.
on the surface pressure. Increased total area of contact (A) reduces
surface pressure P. As a result of this higher limiting speed of 42 m/
sec can be achieved without getting blueing of traveller comfortably,
instead of 36 m/sec for CR-Anti-wedge ring and flat traveller.
Increased production rate: At the identical surface pressure
7.
N
(P = A ) for T-ring, allowable normal force between ring and traveller
(N or FN) for orbit ring will be high. Since N ~ Z (centrifugal force),
higher the permissible normal force between ring and traveller, higher
will be the centrifugal force at which stable spinning is possible.
This can allow ring frame to operate at 30% higher spindle speed
(Ns). Hence limiting speed of the traveller is high, practically higher
spindle speed can be attained, gives increased production rate and
thereby reduced yarn cost/Kg.
Longer life span of ring–traveller: Higher area of contact uniformly
8.
distributed between traveller legs in contact with ring, imparts
uniform pressure. Uniform wearing out of the ring thereby offers
15% longer life span of ring as well as traveller even at higher
spindle speed.
Improved yarn quality: Higher operating speed of the spindle (Ns)
9.
gives rise higher yarn tension (S), as S ∞ Ns3. Higher yarn tension
increases height of node (πP), permits higher balloon height (H),
without causing balloon collapse. Thereby spinning becomes
possible without any need of balloon control ring, liable to cause yarn
damage especially introduce hairiness on rubbing. Thus improves
product yarn quality. Spinning at higher tension also improves fiber
orientation and thereby increases product yarn strength.
4.3.5.1 Life of ring and traveller

The serviceability of ring–traveller depends purely on the allowable extent
of wear. The time period required to reach this limit purely depends on the
intensity of wear and distribution of wear. Conventional rings-travellers were
harder and making only two point contact as mentioned earlier. So, their
wearing out was faster even at slow speed. Their life was between 6 and 10
years on the basis of three shifts working.
Modern orbit ring–traveller follows uniform wear pattern due to surface
pressure acts on larger as well as on entire contact area. Although spindle speed
is hiked by 30% compared to classical ring–traveller, improved metallurgy,
finish applied as well as faster and uniform thermal distribution have limited
rate of traveller wear to low level. That’s why practically attainable life cycle
is no more be different than the conventional one, even though under goes
more stresses.
4.4 Twist
Twist as mention in the beginning, refers spiral turns given to the parallel
strand of fibers for imparting cohesive forces amongst them. The brief mention
about the two important phenomenon, viz., direction of the twist and amount
of twist needs to be defined in relation to ring spinning.
4.4.1 Direction of twist

There are basically two types of twist: ‘S-twist’ and ‘Z-twist’ (Fig. 4.11 (i)).
If the spirals of helical configured yarn matches with the central portion of
letter ‘S’, then it is said to be a ‘S-twist’. It is often called a ‘Reverse’ or
‘Left hand twist’, as inserted due to the anticlockwise rotations of the fiber
strand. Double yarns are usually S twisted, so also known as ‘Double yarn
twist’.
Figure 4.11 Twist direction
If the spirals of helical configured yarn, matches with the central portion of
letter ‘Z’ then it is said to be a ‘Z-twist’. It is often said to be a ‘Regular’
or ‘Right hand twist’, as inserted due to the clockwise rotations of the fiber
strand. Single yarns are usually Z twisted, so also referred as ‘Single yarn
twist’.
4.4.2 Arrangement for setting yarn twist direction on ring

frame
Regular as well as reverse twisted yarns are produced on ring frame as per
end use requirement. So, arrangement for changing twist direction must
be provided on ring frame irrespective of its type. The arrangement can be
broadly classified into two groups: (i) Single motor operated ring frame and
(ii) Multimotor operated ring frame.
4.4.2.1 Single motor operated ring frame

The entire drive to the ring frame gets operated from the one motor located
at head end in this group. All conventional and middle edge ring frames fall
in this category. Again there are two divisions in this group based on mode
of operation: (i) Decentralize arrangement of twist change and (ii) Centralize
arrangement of twist change.
Decentralize arrangement of twist change: Classical ring frame has single
motor drive for the entire ring frame. It is a unidirectional operating motor,
always in forward (clockwise) direction. Thereby driver backelite pulley
receives drive in clockwise direction only. This pulley drives four spindles in
a group via a tape. Two jockey pulley helps in retaining tape tension to prevent
slippage. The position of backelite pulley in the group is thus important in
defining direction of pull exerted on the tape. If it is kept towards tail end
(right hand side) in-group results in clockwise movement of the spindles
(spindle wharves) and thereby gives ‘Z’ twist (Fig. 4.11 (ii)). Similarly its
location towards head end (left hand side) provides anticlockwise turns to
spindle for ‘S’ twist insertion. Thus the system demands shifting of pulley
position in the group for changing twist direction. Reserved Bakelite pulley is
provided at the tail end on the ring frame operating with regular twist for the
purpose. Tapes need remounting for such changeovers. However, the manual
shifting of tape for the individual group adds to machine downtime, adversely
affects productivity.
Centralize arrangement of twist change: Yarn twist direction setting
arrangement is made centralized on the middle edge ring frames. One such
arrangement launched by Rieter on its G5/1 Ring frame is briefly explained
here for the purpose. Similar to classical ring frame it has also tape drive in the
group of four spindles. But the system is equipped with electronic controls.
Reversing switch a11 is provided in main control panel (Fig. 4.11 (iii–b)). The
switch facilitates in setting main shaft (backelite pulley shaft) rotations either
in clockwise or anticlockwise direction as per desired twist direction. Separate
timer belt change wheel is given for retaining forward operational direction
for the rest of the machine parts irrespective of spindle rotational direction
(Fig. 4.11 (iii–a)). Either left hand or right hand side jockey pulley is made
free to rotate for twist direction changed from S to Z respectively. The top
cover of the box made dismantle and reversed for the purpose. The “Rieter”
logo engraved on the top of the cover lies on the left hand side for the Z-twist
and right hand side for S-twist. This guideline ensures correct twist direction
setting, although done manually (Figs. 4.11 (iii) (c–d)). This arrangement has
permitted faster and precise change over for the twist direction for the single
motor driven ring frame.
4.4.2.2 Multi-motor operated ring frame

Latest high speed ring frames are long enough with almost double the number
of spindleage (1600–1800 spindles) as compared to conventional one (440–
880 spindles). The single end control is not precise especially for ring frames
operating at high speed (25 m/min instead of 10 m/min). Thereby individual
motor drive is provided for all the spindles as well as drafting rollers. This
has made operation of each individual spindle independent of other spindle in
terms of speed and direction of rotation. A push button system in the control
panel can serves the purpose of changing spindle direction instead of spinning
technology adjustments on the machine. This can be performed without any
mechanical interventions. However initial investment involved is too high
along with need of skilled labour employment.
4.4.3 Amount of twist

Amount of twist defines number of twist turns inserted per unit length of
drafted strand. It is expressed in terms of twist per inch (tpi) in conventional
set up and in terms of twist per meter (tpm) in modern one. However, both the
expressions are dependent on yarn count to be spun for defining level of twist
present in the yarn. So, Twist Multiplier (TM) or Twist Factor (TF) is used as
a measure for twist level present in yarn structure for English count (Ne) and
Tex yarn numbering systems, respectively. It represents tangent of helix angle
formed by surface fibers with yarn axis. Thus it expresses yarn twist level in
its direct relationship and independent of yarn fineness knowledge.
Figure 4.12(i) illustrates yarn strength and twist relationship, which is of
a main interest for ring spinning. It is clear from the graph that yarn strength
increases with the amount of twist, up to optimum twist level (K). But beyond
that yarn strength drops due to obliquity effect.
Selection of a twist below the maximum strength level is appropriate,
because higher strengths are mostly unnecessary. They cause harsh handle
and poor cover to the end product along with reduction in productivity.
Yarn twist at ring frame is defined as a ratio of spindle speed to the
delivery speed of front roller.
Spindle speed (rpm )
Yarn twist (tpm) = [Eq. 4.5]
Delivery speed (m/min )
The spindle speed is always set at a maximum speed. So, higher yarn
twist can only be obtained by reducing delivery speed. Generalizing, higher
twist can be inserted while working at low production rate. This is further
made clear with an example.
Example: Calculate yarn twist (tpi) for the twist gearing given in
Fig. 4.12(ii) [where, A = 45T, B = 24T, C = 32T and D = 55T].
Figure 4.12 Amount of twist
Now,
Yarn twist (tpm) = [Eq. 4.6]
Hence twist gearing involves information about driving gear train between
spindle and front roller, responsible for twisting only. Relative calculation
need to be done for evaluating yarn twist. Accordingly for unit revolution of
front roller spindle speed is calculated by using gear train. So, Equation 4.6
will take the following shape:
Spindle speed (rpm) per revolution of front roller
Yarn twist (tpm) =
Or
Spindle speed (rpm) per revolution of front roller
Yarn twist (tpi) =
Delivery speed (inches/min)
29 ×102 × 44 × D × B ×115 × 250

\ Yarn twist (tpi) =
26 ×103 × 30 × C × A × 26 × 21× π ×1.06
25.6288 × D × B
=
A×C
25.6288 × 55 × 24
= = 23.5
45 × 32
Example: Calculate delivery speed of the ring frame in m/min for
spinning the yarn at 25 tpi and 32 tpi. Spindle speed is 20,000 rpm.
Yarn twist (tpi) = ;
Delivery speed (m/min ) × 39.34
[\ 1 m = 39.34 inch]
Spindle speed (rpm)
\ Delivery speed (m/min) =
Yarn twist (tpi) × 39.34
25,000
=
25 × 39.34
= 25.42 (m/min); working at 25 tpi
25,000
=
32 × 39.34
= 19.86 (m/min); working at 32 tpi
Thus, front roller speed need to be reduced for working with higher twist
level.
4.4.4 Factors determining amount of twist for ring spun

yarn
Amount of twist required depends mainly on: (i) fiber length, (ii) yarn count
spun, and (iii) desired yarn characteristics.
Fiber length: The obliquity effect arises earlier with short staple (L1)
as compared to long staple (L2) (Fig. 4.12 (i)). Here obliquity effect refers
inclination of constituent fibers to yarn axis by 90 degree or more on twisting.
So, allowable amount of twist employed is less with short staple as compared
to long staple. It varies as per fiber length. Here amount of twist refers TM or
TF. But for doing twist setting on the machine, tpi or tpm value is required.
Therefore relationship of TM or TF with twist per unit length needs to be

defined. They are given by following expressions.
TPI = T.M. × Ne [Eq. 4.7]
 100 
Or TPM = T.M. ×   [Eq. 4.7]
 Tex 
Amount of twist employed also gets changed with the change in fiber
length along with end use of yarn (Table 4.3). The following thumb rule is
employed for calculating warp and weft TM values for known fiber staple
length.
Table 4.3: Twist Multipliers used for different fiber length and yarn end use
Yarn type Short staple Medium staple Long staple
Knitting - 2.5-3.0 2.1-2.6
Weft 3.7- 4.0 3.5-3.8 3.0-3.4
Warp 4.0- 4.5 3.8-4.5 3.4-3.9
Thumb rule: ‘T.M. employed for warp is 4.5 and weft is 4.0, with fiber
having 7/8 inch staple. With every ± 1/16 inch change in length, T.M. gets
changed by ±0.05’.
Similarly twist required for maximum attainable yarn strength for known
fiber staple length (S.L.) of fiber can be calculated by the relationship given
below:
4.25
T.M.maxstrength = [Eq. 4.9]
3
S.L.2
Yarn count spun: The yarn strengths (F) are proportional to the inclination
(helix) angles of the constituent fibers. Hence twist multiplier represents
tangent of this helix angle and for the acute helix angle its value varies in
direct relationship to yarn twist level. However, amount of twist (TPI / TPM)
is affected by yarn count and T.M. as mentioned in previous section. So, two
different fineness yarns with the same strength and twist multiplier must not
possess same twist per unit length. It is going to be more for the finer yarn as
compared to the coarser one. This can be explained with an example.
Example: Two yarns A= 25s Ne and B = 64s Ne are spun with constant
T.M. of 4 to get identical strength. Then, according to Equation 4.9:
TPIA = 4 × 25 = 20
and TPIB = 4 × 64 = 32
Yarn count becomes coarser with twist contraction. Thereby yarn count
on bobbin is always coarser than the count at front roller. The mathematical
relationship between them can be given by following equation:
 % TC 
Yarn count at bobbin = Yarn count at front roller × 1 −  [Eq. 4.10]
 100 
– for indiryect yarn numbering system.
Or
 % TC 
Yarn count at bobbin = Yarn count at front roller × 1 +  [Eq. 4.11]
 100 
- for direct yarn numbering system.
Twist contraction (T.C.) refers the reduction in fiber strand (drafted ribbon
here) on twisting. Its value is dependent on amount of twist employed. It is
higher for higher the twist employed as per the following relationship.
Twist contraction (%) = (2.64 × T.M.) – 4.28 [Eq. 4.12]
Desired yarn characteristics: Yarn spun with low twist execute soft and
docile feel as compared to harsher feel obtained with high twisted yarn. Bulk
of the low twisted yarn is higher due to its loose voluminous structure. Fabric
produced out of such yarns gives better cover and extensibility; normally
preferred as knit yarn and weft yarn in woven structure. Thus amount of twist
used for the yarn formation is also influenced by the end product characteristics.
Table 4.3 gives an account for twist multiplier used for different fiber lengths
as per end use.
4.5 References
Publications.
Economics’, Tailor and Francis.
7. Lorenz R.R.C. (1987). ‘Yarn Twisting’, Textile Progress, Vol. 16, Number ½, The
Textile Institute, Manchester.
8. Pattabhiram T. K. (1997). “Essential Elements of Practical Cotton Spinning” Somaiya
Publications Pvt. Ltd. Mumbai, New Delhi. Fourth Edition.
9. Staldar H. (1992). ‘A new ring and traveller system as the key to more production
from the ring spinning machine’, Indian Journal of Fiber and Textile Research, Vol.
17, pp. 209–214.
10. http://www.rieter.com/cz/rikipedia/.../twist-insertion-and-yarn-formation, ‘Twist
insertion and yarn formation - Rieter’ [Accessed on 12 July 2014].
11. http://www.nptel.ac.in/courses/116102038/23, ‘NPTEL Phase II: Textile Engineering
- Yarn Manufacture - II, [Accessed on 1August 2014].
12. http://www.bracker.ch/products/spinning-rings [Accessed on 1 July 2014].
13. Winterbottom J. (1907), ‘Cotton Spinning Calculations and Yarn Costs’, Longmans,
Green and Co., London.
5
Balloon theory
Abstract: The balloon formed during spinning (twisting) behaves similar to

the string vibrating under adequate tension. So, the same theory can be used
to understand behavior of the whirling fibrous strand during spinning. The
mathematical relationship of variables influencing half wave of vibrating string
has been utilized to derive an expression for spinning balloon node length. Based
on this derivation influence of various spinning process parameters, viz. spindle
speed, yarn fineness and yarn tension, on spinning stability is realized.
Key words: Vibrating string, Wave length, Node, Frequency, Angular Speed,
Spindle rotational speed, Yarn tension, Yarn fineness, Tex, ABC-ring, Lift, Balloon
height, Balloon collapse, Spinning stability, Doffing frequency, Yarn content.
5.1 Introduction
The fiber strand on emerging from front roller nip gets twisted by upright twist
mechanism as explained in the previous chapter. Turns of twist are generated
by a traveller racing on the periphery of the ring. Unsupported length of yarn
between lappet guide and traveller forced outward to form balloon. The bulge
of spherical configuration attained by yarn is controlled by traveller mass,
acting as a tensioner during spinning (Fig. 5.1(i)). Thus a finite balloon can
be formed only when there is some mechanism for maintaining a tension in
the yarn. The balloon so formed during spinning (twisting) behaves similar to
the string vibrating under adequate tension. So, the same theory can be used to
understand behavior of the whirling fibrous strand during spinning. This is used
for identifying permissible process parameters values in spinning section.
5.2 Vibrating string theory in brief

A circularly polarized vibration is obtained when the string under moderate
tension (T) is made to vibrate. The string forms vibration waves similar to
Sine-wave curves (Fig. 5.1 (ii)). According to the terminology of vibrating
string, ‘λ’ represents the wavelength and ‘l’ single node length for a stationary
wave system formed by circularly polarized transverse vibrations of a string.
For small transverse waves in strings,
1 To
Wavelength λ = [Eq. 5.1]
f m
and
radians
Angular velocity of string ω = 2πf [Eq. 5.2]
sec
1 2π
Substituting
= to Eq.5.1, it will take the shape as
f ω
2π To
Wave length λ = [Eq. 5.3]
w m
Where, λ = Wave length in cm,
To = Tension in dynes,
f = Frequency in cycles/sec and
m = mass/unit length in g/cm.
ω = Angular velocity in radians/sec
Figure 5.1 Application of vibrating string theory to ring spinning ballon

Balloon theory 99
5.3 Application of vibrating string theory to ring

spinning balloon
Yarn balloon is formed on emerging from front roller nip and constant speed
rotations given by the traveller, in the spinning zone (Fig. 5.1 (i)). This
spinning balloon in the state of equilibrium is essentially a stationary wave
system formed by circularly polarized transverse vibrations of a string. But
still application of vibrating string theory on ring spinning balloon needs few
assumptions with respect to yarn as well as mechanism.
Regarding yarn characteristics: It is assumed that
i. The yarn is perfectly flexible,
ii. The yarn is inextensible,
iii. The effect of yarn twist is ignored, and
iv. Yarn possesses uniform linear density.
Regarding balloon formation mechanism (twisting): During spinning it is
assumed that
i. There is no air drag prevailing at the point of balloon formation.
ii. Velocity of the yarn along its length is negligible when composed to
rotational velocity.
iii. There is negligible friction present between yarn and lappet guide, so
complete traveller turns are transferred up to front roller nip.
iv. There is no significant difference in traveller speed and spindle speed.
Apart from these, measures taken for yarn, viz. rotational speed, tension
and mass in ring spinning holds different units. So, due mathematical
conversions are needed before implementation of equation 5.3 to spinning
balloon. They are as follows:
I. Rotational speed of the yarn during twisting is same as traveller speed
for no friction between yarn and lappet guide. Hence traveller speed
is considered same as spindle speed ‘n’, measured in terms of 1000
revolutions per minute instead of angular velocity of string ‘ω radians
/sec’.
1000
Hence, ω = 2πn × [Eq. 5.4]
60
Where, n = spindle speed in 1000 rev/min.
Thus ω = 104.7 n [Eq. 5.5]
II. Yarn tension is measured in ‘T’ grams instead of string tension ‘T0’
measured in dynes.
Hence, according to gravitational force theory for earth

To = 981 T grams [Eq. 5.6]
III. Mass of the yarn is expressed as linear density ‘N’ in tex, instead of
string mass ‘m’ measured in gm/cm. According to the definition of
tex, it is N grams weight of 1000 m of yarn length or
N tex = N × 10−3 g/m. Thereby yarn mass ‘m’ in g/cm can be written
as:
m = N × 10−5 g/cm [Eq. 5.7]
Since spinning balloon is related with half wave length (λ/2) or node
length (l) and not the wave length (λ). Thereby translating Eq. 5.3 in terms of
node length (l), it takes shape as follows:
λ π T0
\ Length of single node l = = = πP [Eq. 5.8]
2 2 m
Where, “P” is the product of all variables controlling length of the node.
Simulating length of node with ring spinning balloon, by substituting
respective values of variables [Eqs. 5.5–5.7] in Eq. 5.8. Then expression for
spinning balloon node (l) is
π 981T
\ Length of spinning balloon node l = = πP [Eq. 5.8]
104.7n N × 10 –5
1 981T
Where, P =
104.7n N × 10−5
 T 
\ P = 94.6  2 
[Eq. 5.10]
 Nn 
The height of the balloon (H) must be kept smaller than the length of a
single node (l). Otherwise the rotating yarn interfere the bobbin enhoused
within the balloon, at the point of crossover and results in balloon collapse,
spinning becomes impossible. Thereby balloon height always kept less by
minimum admissible allowance ‘a’ from the length of node (Fig. 5.1 (iii)).
The basic condition for stable spinning in terms of balloon height (H) with
respect to length of node (l) can be given as:
H = 1 + a [Eq. 5.11]
λ
Or H = +a [Eq. 5.12]
2
Balloon theory 101
5.4 Basic conditions for stable spinning

Stability of the spinning demands enough clearance between package and
balloon. Thus, node must not be formed otherwise crossing of yarn at this
point liable to cause yarn to break, known as balloon collapse. Continuously
occurring, this phenomenon will not allow spinning, said as spinning stability
is not achieved. Based on this condition relationship between balloon height
(H) and length of single node (l = πP) can be given as;
1. If H < πP, by minimum admissible allowance “a” then spinning will
continue.
2. If H ≥ πP, then spinning will not continue. As balloon will interfere
enveloped bobbin and yarn gets break. This is due to node formation.
This phenomenon is defined as “Balloon collapse”.
5.5 Spinning parameters influencing spinning

balloon height
Accordingly to the basic condition of stability of spinning balloon (Section
5.4), height of the balloon (H) must be maintained less than πP, where Product
‘P’ is the outcome of all the variables determining length of node (Equation
5.10) in terms of spinning balloon. Thereby variables influencing balloon
height for stable spinning are spindle speed (n), yarn count (N) and yarn
tension (T).
5.5.1 Spindle speed (n)

Spindle speed defines production rate of the ring frame. So, its value is kept
on the higher side. Hence spindle speed (n) varies in inverse proportion to
P (Eq. 5.10), thereby higher the spindle speed (n); lower will be the P and
thereby πP. So, allowable balloon height (H) for stable spinning will be less.
Balloon height is kept higher than bobbin height (lift) for preventing balloon
interference. Thus, for a given machine set up, chances of balloon collapse
increases with larger lift package, while spinning at higher spindle speed. This
situation can be avoided by:
i. Use of smaller lift package to keep H < πP. Modern ring frames
thereby use small lift package to work at higher production rate.
But it reduces yarn content of the package and thereby increases
downtime of the machine due to increased doffing frequency. So,
they are always equipped with auto doffing to reduce down time of
machine. Additional cost due to auto doffing can be paid back by
higher production rate.
ii. Use of longer lift package along with Anti-Balloon Control (ABC)
ring. This will divide single balloon into two equal halves. Thus
resultant height of the balloon is H/2 instead of H (Fig. 5.1(iv)).
Being smaller in height, comfortably meets the condition H < ∏P and
spinning can be continued without causing balloon collapse. Apart
from that use of longer lift package born higher yarn content and
require less doffing frequency, auto doffing is not needed. However,
product yarn quality suffers from disadvantage of hairiness due to
added rubbing with ABC ring.
5.5.2 Yarn fineness (N)

Yarn fineness ‘N’ is expressed in terms of tex, the direct (Universal) yarn
numbering system. Accordingly, higher the yarn number (N), coarser it is and
vice versa. Hence, length of the node (l) is inversely proportional to square
root of yarn number (N) as per above derived relationship (Eq. 5.10). Based
on these influence of yarn, fineness on permissible balloon height is defined.
Finer yarn: Yarn number (N) is less for finer yarn. So, with reduction
in its value, ‘P’ or ‘πP’ increases. Higher the value of πP, allowable balloon
height and thereby lift of the package is more. Use of longer lift package
drops down doffing frequency considerably especially with finer yarn having
slower rate of diameter build up. Conversely with larger size package, tension
variations caused due to traveller acceleration and deceleration is more due
to higher difference in its diameter. Normally smaller lift packages are used
for finer count spinning, even though allowable higher lift packages, mainly
to keep less tension variations. With the use of smaller lift package, balloon
height (H) remains well below πP. So, spinning can be continued without
any need of balloon control ring. This spinning condition is also preferable
in terms of yarn damage caused due to rubbing with balloon control ring for
spinning quality conscious finer yarn.
Coarser yarn: Yarn number N is high for coarser yarn. Going in
accordance to the above discussion, allowable balloon height and thereby lift
of the package is low for the coarser yarn. On the other hand, bobbin diameter
build up rate is also fast with the coarser yarn. So, use of small lift package
results in higher doffing frequency or else higher downtime of the machine
for doffing. Nevertheless this will demand use of longer lift package. But
simultaneously use of balloon control ring becomes mandatory to maintain
balloon height (H) well below πP. However, this will add to the yarn hairiness.
Normally, this yarn damage is ignored against higher production rate obtained
for the comparatively cheaper quality yarn.
Balloon theory 103
5.5.3 Yarn tension (T)

Yarn tension (T) during spinning varies in direct relation to length of node (l).
So, spinning with higher tension, value of ‘P’ (or ‘πP’) and thereby allowable
balloon height ‘H’ will be high. Thus spinning can be carried out with larger
lift package without any need of anti-ballooning device. Addition to this,
spinning at higher yarn tension, the fiber orientation in the yarn matrix will be
better. This aids in improving yarn strength. However, exceeding yarn tension
beyond yarn strength, results in end breaks. Thus, working at higher tension
value is preferable, but must be kept within yarn strength–tension relationship.
Soft twisted knitted yarns possess low strength. Owing to its low strength,
at a given production rate, spinning tension is always kept lower in comparison
to equivalent warp or weft yarn. They are more prone to damage with the use
of ABC- ring, so normally spun with small lift bobbins.
Summarizing the entire discussion, use of balloon control ring is
mandatory in the following situations:
i. Spinning the coarser yarn
ii. High speed ring frames, operating with longer lift package
iii. Spinning yarns at low tension and with longer lift package
5.6 References
- Yarn Manufacture - II, [Accessed on 1 August 2014].
3. Ratnam T.V., Chellamani K.P. (1999). ‘Quality Control in Spinning’, The South
Indian Textile Research Association, Coimbatore.
6
Winding mechanism
Abstract: Winding mechanism lays the yarn on a tapered bobbin by bobbin lead
concept. Traveller in this course acts not only as yarn guide but also a tensioner.
However, interrelated twisting and winding mechanism of ring spinning system
brings about twist variation in yarn due to difference in traveller lag at tip and
base of the bobbin. No doubt they are not significant in their amplitude.
Key words: Winding, delivery speed, traveller lag, tape drive, tangential belt
drive, group drive, individual spindle drive, tape slippage, tape thickness, critical
difference
6.1 Introduction
Winding mechanism deals with the winding of spun yarn. Winding demands
rotating bobbin for winding the product yarn along with yarn guide to lay
yarn on its surface. According to basic winding theory, this exercise can be
performed by using either bobbin lead or guide lead concepts. All the ring
frames are operating with bobbin lead concept for winding. Thus, the main
elements of this section are bobbin (cop), spindle (driver to the cop) and
traveller (yarn guide). Since cop is the invariable part of builder mechanism
also, its features are accommodated in that section. Similarly traveller is also
involved in twisting mechanism, so its details are incorporated there.
6.2 Spindle
Spindle is a shaft for a bobbin with a predefined short length, rotating around
its own lengthwise axis. The spindle firmly supports and drives the bobbin
mounted on it. Rotations of bobbin facilitate winding of yarn delivered by
front roller. The winding is the result of the traveller lagging behind the
bobbin just enough to wrap the delivered yarn around the bobbin. Tension
developed in the yarn on winding thence after drives the traveller resting
freely on it, parallel to spindle. Thus traveller lags behind the spindle speed
by winding revolutions. These rotations of traveller insert the turns of twist to
the drafted strand emerging out of the front roller. Thus spindle performs two
Winding mechanism 105
basic functions of spinning, viz. twisting and winding. However, both of them
demands assistance from the traveller.
6.2.1 Spindle design

A ring frame spindle consists of two main parts, viz. spindle center shaft and
enclosed bearing housing as shown in Fig. 6.1 (i). They are fit together very
accurately and thereby manufactured with very close tolerances. Different
makes and styles of the spindles may look very much alike; the dimensions
of parts are sufficiently different. So, corresponding parts of different models
manufactured by either same or different manufacturers will not fit together.
(I) Spindle centre shaft: It is the active element of the entire assembly.
As the name suggests, it is a shaft for bobbin and thereby supports the bobbin
and rotates it at a desired speed. These rotations of the bobbin are responsible
for twisting and winding actions. The main components of center shaft are
spindle sleeve, blade, oil deflector ring, sleeve whirl or wharve and Let-ON or
clutch (Fig. 6.1 (i–ii)).
Figure 6.1 Ring spinning spindle

(a) Spindle sleeve: It is made up of a light aluminum alloy to reduce

the weight of the revolving mass. It is provided with slight taper at top of
say 1:64. Taper is perfectly matching with bobbin taper to grip it well during
spinning and winding. To ensure that the tube is firmly seated on the shaft, it
has a spring loaded rectangular or circular tube coupling at the top, known as
spindle plug or button.
(b) Spindle blade: It is made up of high grade steel rod, hardened and
tempered. It forms the axis of rotation for the spindle. The lower two-third of
its length is turned to an accurate taper reducing downward, to fit the bolster
bearings in which it will revolve. The upper one-third, approximately, has
a general taper reducing upward, and is made right dimensions to receive
spindle sleeve.
(c) Oil deflector ring: It is a small metal ring, pressed over the lower
end of some spindles (not shown in diagram). It is positioned such that it
will prevent rising of bearing oil too high. Whenever oil reaches to this level
due to high centrifugal forces involved at high speed rotating spindle blades
in bearing housing, it will deflect it back to the reservoir. Thus, it prevents
dropping out of the oil on the floor. So, it is often called “Shield” against oil
spotting.
(d) Sleeve whirl/wharve: The bottom end of the shaft is in the form of a
cap wharve, a hollow grooved pulley, known as whirl or wharve. It receives
drive from the mains via tape. The narrow flanges prevent riding off tape from
either edge or face of the pulley. It is hollow and can therefore be fitted over
the spindle collar accommodated in the bearing housing (Fig. 6.1 (v)). The
tensile forces generated by the drive belt therefore act directly on the bearing,
which favorably influences the smooth running of the spindle. However, the
size of the wharve is important as well as its shape. If its diameter can be
kept small, equally high spindle speeds can be achieved at lower drive speeds
(cylinder/belts). This results in lower energy consumption. However, in order
to ensure that the drive belt rotates the spindle slip-free, the diameter of the
wharve must also not be too small. Wharve diameters of 25 mm to 35 mm
for old ball bearing type slow speed spindle, and 16 mm to 18 mm size with
modern needle bearing type high speed spindle are commonly used. Bearing
section is bolted firmly to spindle rail by nut.
(e) Let-ON or clutch: It is a rounded, metal top to the whirl. It tapers
slightly outward and downward. It is designed to fit inside of and to hold the
base of the bobbin firmly. Modern spindles have whirl combined with clutch.
Usually there is rarely any change made in the design features of center
shaft except in terms of dimension from manufacturer to manufacturer.
(II) Bearing housing: It is the bottom end and the stationary fixed element
of the spindle. It is the lubricating arrangement for the highest speed driven
part of the machine. Thus it is an antifriction device for central shaft of the
spindle. Normally regarded as bolster and fitted in the holes bored in spindle
rail for it. Bolsters are broadly classified in two categories based on its
structural variations;
(i) Regular plain bearing bolster: It is used on conventional slow speed
frame. It is provided with upper sleeve bearing (neck bearing) and simple
hollow cast iron 100–140 mm long and average 10 mm outside diameter
tube. Tube is filled with antifriction oil, circulating through the bolster for
lubrication center shaft blade (Fig. 6.1 (iii)). Bolster is constructed with one
or more vertical slots or grooves in the outside of the top end of the tube.
These slots permits the oil raised up wards due to capillary action to flow
down back into the base for recirculation. Under normal running conditions,
the temperature of the oil in the bolster is 10 to 12 degree Fahrenheit above
the room temperature. If it exceeds beyond 20 degree F, indicates mechanical
trouble. Hence this system does not permit spindle to operate beyond 8000
rpm. So, it is obsolete on modern high speed ring frames.
(ii) Anti-friction bolster: It is the one which is used on modern ring
frame. The antifriction spindle bearing consists of compound of bearings; a
spindle collar bearing and a spindle step bearing. Both parts are connected via
housing. The housing carries oil tube, oil level control and damping device
apart from these bearings (Fig. 6.1 (vi)).
The spindle collar bearing: It comprises a precision roller bearing. The
spindle collar can be a friction bearing or a roller/needle bearing. The noise
level can be reduced considerably by using friction bearings, but energy
consumption is somewhat higher. Most spindles are therefore equipped with
roller /needle bearings.
The spindle collar wharve is rigidly friction-set in the bearing housing
in standard spindles. Bearing vibration is therefore transmitted to the spindle
frame without damping. This results in high noise levels at higher speeds. For
speeds over 18,000 rpm, spindles are therefore mostly used in which not only
the spindle step, but also the spindle collar is attached flexibly to the bearing
housing. These spindles are more expensive, but permit higher speeds and
reduce noise levels in ring spinning machines by some 10 dB compared with
standard spindles. The bearing is often referred as neck bearing as it holds the
spindle in proper lateral upright position and supports the pull of the driving
media (tape/band) used to drive the spindle.
The spindle step bearing: It is a steel-inverted conical step to just fit
the lower tip end of the spindle. According to its shape it is designed as a
conical bearing (friction bearing), and responsible for the elastic centering
and cushioning of the spindle center shaft. An oil-filled spiral mounted
symmetrically with the spindle step ensures optimum cushioning to blade as
well as bolster. Spindle step bearing surfaces carries the weight of the spindle,
bobbin and yarn. It also absorbs all vertical forces acting on the spindle.
The inside diameter of the central part of the bolster is considerably larger
than the blade diameter, leaving enough room for a reservoir of oil. Whereas
outside portion of the bolster is turned to the dimension to fit well within
spindle bore, perfectly in a vertical position. It is also provided with threads
and fixer nut to secure firmly in vertical position on spindle rail. The mounting
of spindle on the spindle rail is called “spindle plumbing”. The accuracy of
plumbing is checked with the help of spindle gauge (Fig. 4.1 (i)). Spindle step
is always a friction bearing and flexible, i.e. it can tilt sideways to a small
extent. The spindle is therefore able to center itself, which enables it to operate
in hypercritical ranges. This results in a significant reduction in bearing forces.
High-performance spindles are inconceivable without damping devices.
Various systems are used, such as damping spirals, damping tubes or damping
oil around a steel tube. If damping spirals (viscous dampers) are used, spiral
spring is compressed at one side when the spindle is deflected to side (Fig. 6.1
(vii)). The oil therefore flows from this side to the other side, where the gaps
become wider. The resistance the oil has to overcome in the process damps the
vibration in the spindle step and ultimately in the shaft. The cavity between
the spindle blade and the bearing housing is largely filled with lubricating oil.
Since the oil is used up, it has to be replenished from time to time. This is
necessary after about 10,000–25,000 operating hours.
6.2.2 The spindle drive

Spindle drive has a considerable influence on the machine’s energy
consumption and noise level. However, the running behavior of the spindle,
especially variations in speed (spindle slippage), balancing errors and
eccentricity relative to the ring, also have an impact on yarn quality and, of
course, on ends down frequency. Badly running spindles have an adverse
impact on yarn quality and economy. So, continuous supervision is essential
to identify such spindles and make them out of production process until
repaired. These spindles are called ‘idle spindles’, they are undesirable for the
production house. Spindle drive options efficiency must be evaluated in these
terms. There are basically three categories of spindle drive:
i. Tape drive
ii. Tangential belt drive and
iii. Direct drive
(i) Tape drive: Fabric tapes are used for driving spindle or spindles in a
group. Conventional ring frame tapes were made up of woven cotton fabric
produced with herringbone or grosgrain weave. They were having 12–20 mm
width and 1.27 mm thickness. Tape ends were overlapped and sewn together
with 2–3 lines of backstitch on regular lockstitch machine. This stitch joint
adds to the thickness. Hard joint continuously knocks with wharves and
thereby off set spindles faster. Even its weight per running yard (meter) was
also high. Such heavier tapes increases power consumption and wear.
Modern ring frame tapes are thereby made up of light but stronger
manmade textile material, mainly nylon. They are spun bonded nonwoven
fabric. Tape ends are fused together or tapered adhesive bonded. Such joint
offers not only reduced joint thickness and hardness but saves spindle setting
for a long duration due to reduced intensity of spindle knocking. There are
two types of tape drive in use: (a) group drive and (b) individual spindle drive.
Figure 6.2 Group drive: Tape drive to spinning spindle
Group drive or four-spindle tape drive: Single tape drives two spindles
on one side of the machine and two further spindles on the other side of the
machine in a group of four. When changing from one side to the other the
tape passes around a drive cylinder (tin roller – old system) or Bakelite drive
pulley (new system) and 1–2 tension rollers (jockey pulleys). Dead weight
or spring loaded jockey pulleys ensure good, uniform tensioning of the tape
(Fig. 6.2 (i)). The power is transmitted to tin roller or pulley shaft via flat or
V-belt from main shaft. Use of lightweight tape and Bakelite pulley offers
less frictional resistance to drive. Thereby force required to drive low mass
frictional bodies is less, consumes less power, and makes drive economical.
Less driving force also reduces tape tension or contact pressure for accurate
drive transmission. Thereby pulley and tape wear get reduced, adds to their
life and also allows working at low noise level. The greater angle of wrap
(110° to 120°) around the smaller diameter wharve guarantees constant
rotation speeds by significantly avoiding tape slippage. This results in
reduced count and twist variations, thus produces better yarn quality. If tape
breaks or need to be replaced, only four spindles are out of production, helps
in realizing higher machine efficiency.
Although, the system has undergone lot of changes to meet with the
requirements of high speed operation of ring frame, it suffers from some
major draw backs:
i. Only one count is spun on the entire ring frame due to common driver
for both the sides of the spindles.
ii. Length of the tape required is 2 m to 2.2 m. Thus long unsupported
length of the tape involved in this drive results in fluttering at high
speed. Even whirling up of fly takes place.
iii. Thin tape, although made up of stronger nylon sandwich material has
shorter life span.
iv. Joint formed to get endless belt gives periodic variations. Even
continuous knocking of this hard and thicker joint with spindle wharve
has a tendency to move the spindle out of center and consequently
need repositioning from time to time.
v. Area below roller beam is occupied by driving elements, demands
extra lighting for maintenance.
vi. Bakelite pulley diameter is normally ranges between 200 mm and
230 mm. Wharve diameter can be reduced maximum to 18 mm, not
beyond that due to limitations of neck bearing size. These will not
permit increase in spindle speed practically beyond 25,000 rpm.
Continuous attempts have been made to overcome these limitations. The
outcomes of these sequences of efforts have been briefly summarized below
along with their associated advantages and disadvantages.
6.2.3 Separate four spindle group drive for each side

Four spindles from one side of the ring frame are driven in a group by tape
(Fig. 6.3 (i)). Two different counts can be spun simultaneously. Tension can
be set easily by varying spring load on changing loading arm height. This
system retains all the advantages of four spindle tape drive. Hence tape length
required is reduced but still long enough.
Direct drive to the spindle: All the limitations associated with the tape
drive originated from the longer length of tape utilized in the drive and its
control at high speed drive. Direct drive to the spindle is the option though off,
to overcome these limitations. Two modes of individual spindle drive have
been designed for the purpose:
i. Mechanical or Individual spindle tape drive (Fig. 6.3 (ii)) and
ii. Motorized direct drive (Fig. 6.3 (iii)).
Figure 6.3 Various unconventional options for spindle drive
Mechanical direct drive: Driver pulley is mounted on longitudinal shaft

and kept in an enclosed box in front of the spindle rail. Tension slide is used
for controlling tape tension. It can be set in position as per tension needed.
Higher angle of wrap at spindle wharve achieved of the order of 110 to 180
degree. This can prevent undue tape slippage and ensures correct spindle
speed, thereby minimizes twist and count variations. Use of considerably
shorten length avoids tension fluctuations and fluff accumulation. This reduces
cleaning, maintenance and floor space requirement. Only one spindle remains
idle in case of break or repairs. Stronger, lighter tape with precise fusing also
offers longer lifespan and thereby lowers down tape change frequency.
Motorized direct drive: Individual spindle motors drive concept, has
been introduced on an experimental basis by the SKF company. Motor drives
directly the spindle mounted on its axis. Thus problematic tapes are eliminated
fully. Even there is no need of any driving accessories like pulley, shaft, jockey
pulley, tension adjuster, etc. Clean and clear space is available below the roller
beam provides ease to maintenance and setting. All the motors are working in
synchronization with front roller motors via inverter control. This set up helps
in varying twist with the fingertip control.
Here each spindle operates individually, so deals with different count
simultaneously. At the moment of break down or maintenance only one
spindle remains out of production. However, the initial cost of the system
and power consumption is high for this conceptionally attractive system. So,
in commercial short staple spinning systems only group drive in the form
of 4-spindle tape drive or tangential belt drive is usually used.
6.2.4 Tangential belt drive

Tangential belt is coming from the suspended drive motor passes along the
back of all the spindles. A large number of pressure rollers (pressure spring)
ensure that the belt is pressed uniformly against all the spindles. A fundamental
distinction is made between three basic forms: single-belt, double-belt and
group drive (Figs. 6.4 (a–c)).
In the first case, an endless belt drives the spindles on both sides (Fig. 6.4
(b)).The second system involves two belts, one of which drives the spindles on
one side, and the second those on the other side (Fig. 6.4 (a)). The double-belt
system results in more uniform spindle speeds. With the single-belt system,
differences can arise due to the widely differing tension in the belts, especially
on long machines. Group drive is being used increasingly nowadays instead
of the single or double-belt version (Fig. 6.4 (c)). In this system a tangential
belt drives 50 spindles on each side of the machine, for example, i.e. 10 group
drives with 10 motors operating synchronously are needed for a machine with
1 000 spindles. Speed synchronization must be guaranteed. In another group
drive system only 1 tangential belt is used. However, this belt is then driven
by several motors operating synchronously along the length of the machine.
The tangential belt system offers many advantages over tape drive:
a. Longer unsupported length of the tape is not involved in this drive.
Thus fluttering at high speed and whirling up of fly are eliminated.
b. Endless belt is used, eliminates periodic variations caused due to hard
and thick joint.
c. Area below roller beam is more open, thereby extra lighting is not
required for maintenance. Less air disturbance under the machine and
perhaps rather less maintenance effort.
Figure 6.4 Various modes of tangential belt drive
d. Higher speeds can be attained by using larger diameter of driver

pulley, kept in horizontal plane at the end of the machine.
e. Strong nylon sandwich belt is used. It has long shelf life. So, frequency
of changeover is very less.
However, it also suffers from limitations like:
i. Higher initial cost of the belt.
ii. Replacement of the belt demands stoppage of the spindle for either
entire machine, per side or group as per the type. Reduces efficiency
and add to the production loss.
iii. Small angle of wrap [< 90°], increases slippage , thereby speed
variation
iv. Higher force is required to drive heavy, long belt against spring loaded
tension clips. So, power consumption is more as well as wearing out
of the wharve is also faster.
v. Higher noise level adds to statutory limitations.
vi. Springs are used for tension clips, although of good quality, loses
their elasticity against continuous higher surface pressure, increases
belt slippage.
6.3 Cop winding

Winding revolutions (Nw) refers number of bobbin rotations used to wind the
yarn delivered by front roller. Thus winding speed is equal to delivery speed
of the machine.
\ πdf Nf = πdbNw [Eq. 6.1]
or Nw = πdf Nf/πdb
Where, df, db represents front roller diameter, bobbin diameter and front
roller rotation, respectively.
The basic need for winding to take place is difference in the revolving
speed of guiding element (traveller) and driving element (spindle).
\ Nw = Ns – Nt [Eq. 6.2]
Front roller delivery speed is constant throughout doff, thereby it becomes
utmost important to keep this speed difference also constant. The situation
becomes bit tough with positively driven spindle and negatively operated yarn
guide; traveller in ring spinning. As traveller, is dragged around the spindle
(bobbin) by the pull of yarn. The speed difference arises through more or less
strong braking of the traveller on the running surface of the ring. Influence
can be exerted on this process by way of the mass of the traveller. Thereby
desirable traveller speed to keep this difference constant can be calculated as
follows:
Nt = Ns – (πdf Nf)/(πdb) [Eq. 6.3]
6.3.1 Influence of winding speed variations during doff

on yarn twist
During ring frame winding, diameter of winding changes continually with
raising and lowering of the ring rail, as the winding layers are formed conically.
Winding speed is changing with bobbin diameter (db) for constant front roller
delivery speed [Eqs. 6.2–6.3]. Accordingly traveller speed also changes,
slower with smaller bobbin diameter and higher with larger diameter. Thus
the traveller must have different speeds at the base and the tip of bobbin. This
can be explained with an example.
Example: Calculate traveller speeds at the base and tip of the bobbin
wound at a spindle speed of 18,000 rpm. The bobbin diameters of 46mm at
the base and 25mm at the tip, and a delivery of machine is 25 m/min,
According to Eq. 6.3, Traveller speed at the bobbin base (Ntb) will be,
Ntb = 18,000 – 25,000/(π×25)

= 18,000 – 173 = 17,827 rpm
And traveller speed at the tip of the bobbin (Ntt) be,
Ntt = 18,000 – 25,000/π × 46
= 18,000 – 318 = 17,682 rpm
Thus twist variations at the base and the tip of the layer is thereby likely, as
twist inserted to the drafted strand depends on traveller revolution. However,
these variations are not significantly different. In the above mentioned
example twist per meter at the smaller and bigger bobbin diameter are 713.08
and 707.28 respectively as per following relationship.
Traveller rpm
tpi = [Eq. 6.4]
 inches 
Front roller delivery speed  
 min 
Percent critical difference in twist per unit length is thereby
Difference in the twist values ×100
% Critical difference =
Average of twist values
= 0.8167
This is less than 1%, so not significant. Thus change in the traveller speed
throughout cop winding is not bringing about any significant twist change in
ring spinning.
Apart from this other variables of spindle drive also plays an important
role in defining twist characteristics of the product yarn. The impact of
different variables and their net effect on twist characteristics of the yarn is
elaborated here.
6.3.2 Variables affecting actual spun yarn twist

characteristics
Theoretical twist values are set on the machine by considering spindle speed
instead of traveller speed. This is mainly attributed to negative mode of
traveller drive, which demands additional calculation in the course. Even as
mentioned in earlier section there is no significant difference in twist value
predicted by using spindle speed in place of traveller speed. The variables
having influence on actual yarn twist value in comparison to theoretically set
one are:
1. Tape slippage
2. Tape thickness
3. Traveller lag and
4. Twist contraction
(1) Tape slippage: The most preferable of spindle drive is tape drive due
to its higher accuracy owned by higher angle of wrap (110–120) as mentioned
in earlier section. But frictional mode of drive introduces slippage of the
order of 3%. Thereby twist inserted to the spun yarn is accordingly less than
theoretically calculated and set with twist gearing.
(2) Tape thickness: Twist calculation involves only driving gear ratio
between front roller and spindle. But tape thickness value is ignored being
thinner. This differs theoretically calculated one from actually inserted in yarn
by 4–5%. This can be well elaborated with an example.
Example: Spindle driving pulley speed is 1,000 rpm and its diameter
is 200 mm. Tape of 1.6 mm thickness is used for driving wharve of 25 mm
diameter.
Theoretical spindle speed (by neglecting tape thickness)
200 ×1 000
= = 8,000 rpm.
25
But
Actually attainable spindle speed (by considering tape thickness)
201.6 ×1 000
= = 7,579 rpm.
26.6
The percent critical difference between actual and theoretical speed is five
percent. Thus actually attainable spindle speed is five percent less in practice
due to tape thickness.
(3) Traveller lag: Traveller due to its own mass and friction with the ring,
resists motion and can be pulled around only when the yarn between the front
roller and bobbin is tight enough (i.e. winding is done). Thus traveller speed
is always less than the spindle speed by winding revolutions. This short fall
in traveller speed is known as traveller lag. Since winding revolutions are
defining traveller lag, it purely depends on diameter of the bobbin for constant
delivery speed of ring frame.
This can be explained with above mentioned example only. Assume a
spindle speed of 18,000 rpm, the bobbin diameters of 46 mm at the base and
25 mm at the tip, and a delivery of 25 m/min, the traveller speed at the tip (Ntt)
will be,
Ntt = 18,000 – 25,000/π × 25

= 18,000 – 318 = 17,682 rpm
And at the base Ntb be,
Ntb = 18,000 – 25,000/π × 46
= 18,000 – 173 = 17,827 rpm
Thus traveller lag at smaller and larger bobbin diameter is 318 rpm and
173 rpm respectively.
Percent loss in twist due to traveller lag:
At larger bobbin diameter; %Ll = 173 × 100/18,000 = 0.96%;
and
At smaller bobbin diameter; %Ls = 318 × 100/18,000 = 1.76%.
Average percent Twist loss due to Traveller Lag = 1.36 %
(4) Twist contraction: Parallel strand of straight fibers, on attaining helical
configuration of twisted yarn, get reduced in length. The shortening in yarn
length on twisting is known as twist contraction. It is purely influenced by the
amount of twist inserted. Higher the twist, higher will be the twist contraction
and vice-versa. Hence over the turns of twist generated by traveller, gets
distributed uniformly over this shorten, actually delivered length than longer
theoretically set one. As a result product yarn carries more twist than calculated
one due to twist contraction. Addition in twist is higher with high twisted yarn
and low with soft twisted yarn. Average addition of twist at low twist per unit
length is 3%, and at high twist per unit length 8–10%.
(5) Net effect on product yarn twist variation: Out of the four variables
discussed above first three reduces twist inserted to the product yarn so given
negative sign. Whereas fourth variable allotted with positive sign as it adds
to the inserted twist. Even percent change values are rounded off for ease of
explanation. Thus percentage twist variation is due to:
1. Tape slippage (−3%)
2. Tape thickness (−4% to −5%)
3. Traveller lag (−1% to −2%)
4. Twist contraction (+8 % to 10%)
Thereby resultant effect of these variables on yarn twist variations will be
either (−3 – 4 – 1 + 8 = 0 ) or (− 3 − 5 − 2 + 10 = 0), means nil. Thus it is clear
that there is no harm to start with spindle speed instead of traveller speed for
the computation of yarn twist.
6.4 References
Publications.
Economics’, Tailor and Francis.
7. Lorenz R.R.C. (1987). ‘Yarn Twisting’, Textile Progress, Vol. 16, Number ½, The
Textile Institute, Manchester.
8. Pattabhiram T. K. (1997). “Essential Elements of Practical Cotton Spinning” Somaiya
Publications Pvt. Ltd. Mumbai, New Delhi. Fourth Edition.
9. http://www.rieter.com/.../ring-spinning/...spindle/...spindle.../4-spindle-tape-drive,
[Accessed on 12 July 2014].
10. http://www.rieter.com/en/.../ring-spinning/...of...spindle/the-spindle-bearing
11. http://www.rieter.com/cn/.../ring-spinning/structural...spindle/spindle-structure,
- Yarn Manufacture - II, [Accessed on 1August 2014].
7
Builder mechanism
Abstract: The ring spun yarn is wound on the spindle-driven cop in association
with traveller, acting as a guide and tensioner. Traveller receives angular
movement on ring via yarn tension and simultaneously linear movement from
ring rail. Thus bobbin building and winding both the mechanisms are going
together. Builder motion has to lay yarn on the entire length of package in a
peculiar pattern. Three types of building patterns are used in the production
course, viz. warp wind, weft wind and assembly wind. Except few exceptional,
majority of the ring frames follow weft wind pattern only. So, the present chapter
is restricted to these ongoing practices only.
Key words: Bobbin, cop, builder mechanism, weft wind, layering traverse,
switching traverse, cop heel, shoulder heel, under winding, back winding, reserve
coil, builder cam, ring rail, ABC-ring, lappet guide, damping cylinder, servo grip
7.1 Introduction
Previous chapter has given an account for winding mechanism. The ring spun
yarn is wound on the spindle-driven cop in association with traveller, acting
as a guide and tensioner. Traveller receives angular movement on ring via
yarn tension and simultaneously linear movement from ring rail. Thus bobbin
building and winding both the mechanisms are going together. Traveller
is mounted on ring carried by ring rail. This ring rail has given continuous
layering traverse and switching traverse to lay yarn on the entire length of
package in a peculiar pattern. The pattern observed for laying the yarn on the
cop (bobbin) is referred as bobbin building. Three types of building patterns
are used in the production course, viz. warp wind, weft wind and assembly
wind. Except few exceptional, majority of the ring frames follow weft wind
pattern only. So, the present chapter is restricted to these ongoing practices
only.
7.2 Ring frame bobbin

A spinning bobbin (Figs. 7.1 (i–ii)) is a long narrow cylinder, made up of
paper, cardboard or high density plastic. Its height (LH) is ranging between
180 mm and 260 mm. More the height of the bobbin, the more yarn can be
accommodated on it, allows ring frame to work with reduced doffing frequency.
Some height, 10 mm at the top as well as bottom, remains uncovered by yarn
during bobbin build up. The height used for winding the yarn is known as lift
of the bobbin (LG). Bobbin is also slightly tapered at the top with the taper
angle 1:38 to 1:64. The inside dimensions of the tube are made to make it
perfectly fit on the spinning spindle. Tubes are stable and rigid enough. They
are designed for the particular set of spindles and thereby cannot be used on
spindles of different size or design. The outer surface of the tube is used for
winding the spun yarn without undue slippage, thereby it is provided with
engraved lines.
7.3 Structure of cop

The word ‘cop’ refers the output package of the ring spinning machine.
It consists of three visually clearly distinguishable build up sections (Fig. 7.1
(iii)):
i. Cop heel: The lower, barrel-like rounded base
ii. Main body: The middle, cylindrical section
iii. Shoulder heel: The conical convergent tip or nose
7.4 Cop building pattern

The specific shape of the cop is created by the weft wind pattern. It composed
off tapered application of a large number of individual layers of yarn, one on
top of the other. The winding begins in the base portion of the bobbin with
almost cylindrical layers on the cylindrical bobbin tube (Fig. 7.1 (iv)). The
winding point is shifted upward by very small amount after laying each two
layers: one upwards and second downwards. The initial layers are conical in
shape, thicker at the base and thinner at the tip. With the deposition of one
layer on another of these conical layers, the conicity gradually increases.
Each of these layers consists of a main layer, also called as winding
layer and a cross layer, also called as binding layer (Fig. 7.1 (iv)). The main
winding, which primarily has to take up the yarn, is usually formed as the
ring rail slowly rises, individual coils being laid close to each other or on each
other. The main layers are the effective cop filling layers. The cross layers are
made up of widely separated steeply downward-inclined coils of yarn and are
formed during rapid lowering of the ring rail. Since the cross windings are laid
diagonally between the main windings, they isolate the latter from each other.
This prevents entire layers from being pulled off during high speed unwinding
Builder mechanism 121
of the cop in downstream processing, known as slough off. In the absence of

such separating layers, individual yarn layers would inevitably be pressed into
each other and layer-wise draw-off of yarn would be impossible. However,
this type of winding or bobbin building requires a complicated mechanism
and winds the yarn with continuously changing tension.
Figure 7.1 Cop structure
7.5 Builder mechanism

It refers the set of basic mechanisms required on the ring frame machine, for
building up the cop of desired shape and dimensions. They are:
i. Layering traverse: Continuous rising and lowering of winding point
in order to apply alternate main and cross windings and
ii. Switching traverse or advancement of starting point of layer:

Continuous ascent in very small amounts after each layering traverse
in order to fill the cop.
Apart from the basic mechanisms it requires auxiliary mechanisms. They
assist in accommodating maximum yarn length relative to bobbin diameter
and maintaining minimum end breaks. They are:
I. Cop heel and shoulder heel formation: The accommodation of
more yarn on bobbin is facilitated by cop-heel and shoulder- heel
formation. The tip and base of the cop is tapered, if formed by normal
lay of yarn by builder mechanism. Due to tapered shape, enough gap
is left between ring and bobbin outer diameter. So, yarn content of the
bobbin is increased by accommodating more quantum of yarn at the
base as well as tip of the bobbin. Thus cop-heel formation deals with
the rounded base formation instead of tapered one due to deposition
of more yarn layers in less space. Hence, shoulder helps in preventing
slough off in the subsequent processes during unwinding; amount of
extra yarn wound is less in comparison to the base of the bobbin.
Thereby it resumes conical shape instead of round barrel shape base
of the bobbin.
II. Synchronized traversing of lappet guides and ABC rings along with
ring rail: End breakage rate is controlled by keeping yarn tension
during winding less than yarn strength. The factors influencing yarn
tension during the course of bobbin build up are mainly two: balloon
height and winding on diameter of the bobbin. The resultant tension
of these factors is well controlled by well-organized synchronization
between traversing of ring-rail, lappet guide and balloon control ring.
III. Under winding and snarl removal: Efficiency of the ring frame is
adversely affected by its higher down time. So, restarting of the ring
frame must be as speedy as possible after doffing. This demands
yarn threading must be retained for the next doff to avoid higher
downtime for piecing to restart. Under winding mechanism is
designed to wind few (4 to 5) coils loosely below the base of the
bobbin on the completion of cop build up. These coils on doffing slips
off the spindle and helps in retaining threading for the next doff in the
sequence. However, on shifting the ring rail to the staring position
after under winding generates yarn slackness between front roller and
traveler. This leads to snarl formation due to slacken higher twisted
length, results in end break. This requires snarl removal mechanism
in association with under winding.
7.5.1 Layering traverse

Cop build up demands winding off number of layers on the bobbin. Each layer
comprises a main layer, also called as winding layer and a cross-layer, also
called as binding layer as mentioned above. The main layers are the effective
cop filling layers and thereby individual coils being laid close to each other
or on each other. This demands more time for laying winding layers on the
bobbin for the constant delivery speed of the front roller. So, the main layer
is formed during slow rising of the ring rail. The cross layers are made up of
widely separated steeply downward-inclined coils of yarn and they are mainly
designed for locking the densely populated winding layers to prevent slough
off at the point of high speed unwinding on the subsequent processes. They are
less in number and covering the same bobbin area. Therefore at the identical
delivery rate, time required for their laying on the bobbin is less. Binding
layers are thus formed during rapid lowering of the ring rail. A yarn length
ratio of about 2:1 (old) or 3:1 (new) between the main winding (upward) and
the cross winding (downward) results due to difference in the pace of ring rail
movements. The total length of each double layer should be no more than 5
m (better 4 m) for unwinding purposes. This length is also referred as length
delivered per double traverse. The layering traverse of the ring rail is ideal if
it is some 15–18% larger than the ring diameter.
Schematic diagram of one such traversing mechanism used on Ring frame
LMW LG5/1 is shown in Fig. 7.2(i). Rising and lowering of the ring rail is
caused by the heart shaped cam known as traverse cam and many a times
referred as builder cam. This movement is transmitted via a follower fitted on
a builder arm and a set of nylon tapes and pulleys to the ring rail.
Ring rail is connected with nylon tapes at regular distance. Nylon tapes
allows ring rail to hang with its entire weight. The rear ends of the tapes are
connected with pulley mounted on a shaft. The arrangement is true for both
the sides of ring rails. Another tape connects the pulley compound with it to a
segment pulley (cam), which in turn connected with a builder arm via a tape.
The tape wrapped round guide disc fitted on arm and finally get wound on a
tape take up drum.
A worm receives the drive from the main gearing provided at the head end.
It transfers the drive to the worm wheel in meshing, mounted on the shaft of
traversing cam. Thus traverse cam gets the driven. Long flat part of the heart
shaped builder cam pushes follower roller pressed against it downward and also
treadle lever down, as follower housing is fixed on the treadle lever. Downward
displacement of treadle lever forces builder arm (doffing lever), connected
with it, also down along with guide disc (tape pulley d). This pulls tape down
and transfers this movement to the ring rail via a set of pulleys and respective
tapes. This results in the slow upward displacement of the ring rail for laying
winding coils. The short steep portion of cam causes downward movement of
ring rail via the same channel but the operating force is generated by the weight
of the ring rail assembly. This downward movement of the ring rail is thereby
rapid but with decreasing speed. Fast downward displacement of the ring rail
is responsible for laying binding coils. Thus builder arm is continuously raised
and lowered with the tape pulley due to the rotation of the cam and mass of ring
rail assembly. The cam is driven positively from the main drive via lay gearing.
The gearing responsible for laying yarn coils on the bobbin is referred as lay
gearing. The up and down movement of doffing lever transmitted to the ring rail
via pulleys and the tapes is known as layering traverse.
Figure 7.2 Traversing motion (LMW G5/1)
The vertical displacement of ring rail with respect to bobbin in either of

direction is referred as traverse length. The traverse length can be altered by
displacing follower roller closer or away from the fulcrum in treadle lever
housing for the constant stroke of the cam. Mounting follower away from the
treadle lever fulcrum, increases traverse length and vice versa.
7.5.2 Switching traverse

Ring rail carries a guiding element for yarn winding; traveller. As mentioned
above traverse length is always shorter than the lift of the bobbin. Thereby
ring rail has given a continuous ascent in very small amounts after each
layering traverse in order to fill the entire cop, referred as switching traverse
or advancement. This movement should not interrupt operating of layering
traverse but works in a synchronization with it.
Again an account is given to LMW G5/1 Ring frame for explaining
operational mode of switching traverse. It consists of a worm wheel on the
builder cam shaft, receives the drive from the mains gearing (Fig. 7.3). It
carries on its back side 1–3 driver pins fitted in the slot and at equidistance.
The mounting of number of pins depends on the rate of advancement desire.
Higher the number of pins on worm wheel, faster the advancement and so on.
Rotation of the wheel during layering traverse also rotates the pin/s around
the shaft. This movement of the pin/s makes the sector loosely suspended
behind the worm wheel to be raised along. Upward ascent of the sector moves
small pinion in its meshing to rotate anticlockwise. Pawl lever fashioned on
the pinion shaft gets the similar angular displacement and makes the catch
to turn the advancement ratchet wheel in an anticlockwise direction. This
small turn of ratchet wheel is given to tape drum connected to the ratchet
wheel via gearing. The movement is such that the tape gets wound in a small
amount onto the drum. Thus, shortens the tape length available between tape
drum and guide pulley fitted on doffing lever. This increases tape tension
and enforces set of pulleys, tapes, cam and shaft to rotate for compensating
shorten length and results in a slight rising of ring rail. This upward shift of the
ring rail switches next traverse to commence from the new position. Thereby
this mechanism is referred as switching traverse. The amount of upward
displacement is known as advancement. Its magnitude gets varied as per the
adjustable stroke (angular displacement) of pushing pawl and can be read off
from the advancement dial. The downward displacement of the sector is due
to its own weight and that will make the catch to slip past the ratchet wheel
teeth.
7.5.3 Cop heel formation

The cop base is made convex in order to accommodate as much yarn as possible
on the cop (Fig. 7.1(ii)). This convex shape results partly automatically from
the specific type of winding, but is also reinforced to some extent by an
auxiliary mechanical device, known as a cam, cog, deflector or also by other
names (Figs. (7.2–7.3)).
The cop heel formation mechanism commence in the beginning of doff.
Ring rail lifts and lowers due to constant linear displacement(s) given to doffing
lever by traverse cam. This linear displacement of lever gets converted to
angular displacement (θ = s/r) for pulleys, connected via tapes. However, the
cam attached to the pulley before the cross shaft, projects over the periphery
of pulley, adds to the working radius (r) of the pulley by its length (l). As a
result of this when winding on the empty cop commences, cam deflects tape to
some more degree, as shown in Fig. 7.3. Thereby angular displacement earn
by the next pulley (mounted on cross shaft), in sequence is less than actually
transferred by the cam in normal course, viz. θ(cop heel) = s/(r + l) instead of
θ = s/r. Because, part of the linear displacement (s) of the tape arising from the
rise of doffing lever is not passed on to the ring rail, but get lost as deflection
at cam. The ring rail traverse no longer corresponds to the specification, it
becomes smaller. The heart-shaped cam (builder cam) and the delivery roller
are coupled together by the drive gearing. Thus, the length of yarn delivered
for each revolution of the cam is always the same. Since the yarn delivery
length per traverse remains unchanged, the bulk (yarn coils) per layer wound
on the bobbin is increased. This result in the more densely populated cop base
having convex shape instead of flat tapered one.
Figure 7.3 Switching traverse mechanism (LMW LG5/1)

The position and design of the cam is selected such that the height of the
layer increases gradually, till it moves totally away from getting in contact
with the tape. This is attained by winding of the tape on the take up drum for
each double layer formation (layering traverse). The tape winding drum is
turned continuously to the left after each layering traverse in small amounts
by the winding ratchet wheel of switching traverse mechanism in the further
course of spinning (Fig. 7.3). Winding of the tape on take up drum makes
pulleys involved in the drive, to turns in the right in equally small amounts.
This moves cam (segment) away from the working region of the tape and
thereby, the cam is increasingly less engaged. The rounded surface of pulley
now offers smaller working radius (r) to the tape. So for the given constant
linear displacement (s) of builder cam, angular displacement (θ) earn by the
pulley on cross shaft becomes more. Once this stage is reached, the heights
of the further layers do not change till the end. Thus after base formation the
entire movement of the tape is passed on to the ring rail and the cop builds up
normally.
Figure 7.4 Basic phenomenon of convex base formation
The base of cop formed is spherical convex instead of flat tapered one.
This cop base build up phenomenon is explained in Fig. 7.4 (i–iii). The
volumes of the individual double layers are equal for the constant delivery
rate of the frame. Hence tapered bobbin is used, deposition of double layers on
the tube begins with a small average layer diameter d1. The average diameter
increases gradually with each newly deposited layer from d1 to dn. During cop
heel formation winding is carried out with constant layer volume but with
increasing height of the layers as explained above. Thus in the beginning of
the doff, the layer width goes on reducing from b1 to b2 to b3, and so on till
the height reaches fixed level (cop heel formation ends). Since the ring rail is
also raised by a constant amount ‘h’ after each deposited layer, by switching
traverse. The base shape resumes the curve, rather than straight line. Thus
convex shape arises automatically in the base portion.
Conical layers instead of cylindrical layers are formed throughout the cop
building. The non-uniform movement of the ring rail results in the formation
of the conical layers. Hence ring rail speed increases during upward movement
and falls during downward movement. As a result of this at the tip of each
layer winding tension is higher than at the base of the layer. Because the ring
rail does not dwell as long at the tip, as it does at the base. So, less material
gets wound at the tip makes the layer thinner at the tip (Fig. 7.1 (iii)). Cop
build up is mainly influenced by this non uniform movement of the ring rail
and well explained with a numerical figure (Fig. 7.4 (iii)).
If the ring rail is assumed to be moving twice as fast at the top of its
strokes as at the bottom of the stroke, the first layer would be half as thick at
the top as at the bottom, i.e. b1/2 instead b1. The first layer would correspond
to a trapezium with the side b1 at the bottom and the side b1/2 at the top. This
is followed by the deposition of the second layer. Owing to the lifting of the
ring rail, the upper portion of the new layer would again be deposited on the
bare tube. The average diameter at the top would be the same as that of the
first layer, and the volume, and hence the thickness, would also be the same,
that is b1/2. Each newly deposited layer will have this thickness of b1/2 at the
top. At the bottom, however, the diameter is increasing continually, the layer
thicknesses decline from b1 to b2 to b3 to b4…as explained above. Accordingly,
continually narrowing trapezium are produced. At some stage, the trapezium
will become a parallelogram, i.e. the lower side will be the same size as the
upper side: both will be b1/2. Since all other winding conditions now remain
the same, no further variation can now arise in the layering. One conical layer
will be laid upon the other until the cop if full, that is when the cylindrical
portion of the cop is formed.
7.5.4 Shoulder heel formation

It operates on the same phenomenon of cop heel. But it differs in terms of
position or timing. It deals with the spherical tip formation of the cop in place
of tapered one in order to increase yarn content of the bobbin. The building
concept is same as that of cop heel formation, use of segment, cog or projection
to vary the angular displacement of the pulley and thereby traverse length.
However, high speed unwinding of such cops on the winder significantly
rises sloughing off tendency. This is totally an undesirable condition for
productivity of the next machine in sequence. So, now-a-days with high speed
winder shoulder heel formation mechanism has not found place on high speed
ring frames.
The gear train transfers drive to the builder cam from the front delivery
roller is known as lay gearing. It defines the cam speed in relation to the
front roller delivery speed. Thus coil density on bobbin for ring rail double
traverse gets affected by the size of lay gear. If lay gear with too many teeth
are inserted, cam moves fast and the final condition of constant conical layers
will be reached too soon and the cop tip will be too thin. Similarly it will be
too thick if the ring rail is lifted too slowly. Thus shape of the cop tip is mainly
influenced by the size of lay gear.
7.5.5 Synchronized traversing of ring-rail, lappet guide

and balloon control ring
The desired cop structure is obtained with the two basic mechanisms of builder
motion: traversing (layering traverse) and advancement (switching traverse).
A solid- heavy spindle rail possesses positively driven and high speed
revolving spindles on it. Thus performing frequent up and down movement at
accelerating and decelerating speeds for layering traverse via moving spindle
rail is not an economical and practically viable option. So, layering traverse is
always performed with the less complicated and light weight moving ring rail
only on all ring frames.
Conversely switching traverse involves comparatively smaller amount
unidirectional displacement after each layering traverse. This can be achieved
in two ways:
i. Moving ring rail: Ring rail is ascending by small amount after each
double traverse. The system described above and popularly used on
all modern ring frames, and
ii. Moving spindle rail: Spindle bearing plate is lowered by small amount
after each double traverse. The principle was adopted by Rieter
long back in year 1940. The logic involved was constant tension
spinning by controlling balloon height almost constant. As upward
displacement of ring rail after each layering traverse, shorten balloon
height and brings about within bobbin variation. Thus by keeping
ring rail position fixed and performing advancement via spindle rail
can help in keeping balloon height constant, major contributor to
yarn tension. Thus it facilitates in reducing within bobbin variations
due to spinning tension change during cop build up. However, the
system not found commercial success due to complications involved
in practical implementation of theoretically fascinating mechanism.
The difficulties were observed in retaining constant belt and tape
tension used in spindle drive. Consistency in spindle drive was lost
due to increased slippage. The system was not found beneficial
although started with logical thought of controlling root cause for
within bobbin variations. Nowadays all modern machines operate
exclusively with a moving ring rail. But influenced by Reiter’s way
back thinking, they all are equipped with auxiliary mechanisms for
controlling working balloon height almost constant.
Ring rail as on today, performs two types of movements throughout the
cop build up:
• Continuous traversing and
• Shifting upward by constant amount after each double traverse.
Both the movements of the ring rail have an adverse influence on spinning
tension. In particular, the size of the balloon and the winding diameter on
the cop are never the same. Their relationship with spinning yarn tension is
well explained in earlier sections. Tension variations caused due to change
in winding diameter are totally unavoidable. As they are attributed to the
tapered shape of the bobbin and cop build up pattern adopted during winding.
On the other end, balloon diameter is always controlled by using practically
optimized traveller mass in order to avoid balloon collapse or balloon slashing.
So, balloon height is the only left behind variable, need to be controlled.
However, its value is continuously changing with each coil and layer winding.
Efforts must be made to maintain balloon height almost constant throughout
spinning in order to control spinning tension variations.
Anti-Balloon Control (ABC) Ring is designed to divide single balloon
into two equal sizes and thereby reducing spinning tension, as mentioned
earlier. It is therefore kept right at the middle position to that of thread guide
eyelets and ring rail, between which balloon forms. If balloon control rings and
thread guide eyelets are kept at fixed positions for moving ring rail throughout
bobbin build up, the balloon height will change continuously according to
the change in ring rail position. These results in within bobbin yarn tension
variations. Balloon control rings and thread guide eyelets have also been given
traversing and advancement in synchronization with ring rail, via the same
operating mechanism to avoid larger fluctuations in balloon height. However
their movements are albeit by smaller amounts in both layering and switching
traverse (Fig. 7.3). Hence the magnitude of movements is restricted by the
spinning geometry.
The mechanism includes different traversing and advancement strokes for
all the three parts moving in synchronization. So, the driving mechanism up
to driver shaft (Cross shaft) is common for all the components (Figs. 7.2–7.3).
But balloon control ring rail and thread guide eyelets board are suspended
on proportionately smaller diameter driven stepped pulleys via tapes. The
cam pulley transfers the drive to driven pulley on cross shaft. This pulley
is compounded with driver pulleys of ring rail, lappet guide and ABC-ring.
So, they are also raised and lowered along with ring rail in synchronization.
However, steps (diameters) of driver pulleys for ABC-ring (DABC) and lappet
guide (DLG) are rather smaller than driver pulley for ring rail (DRR). That is
DRR > DLG > DABC. Thus for the constant angular displacement (θ) received
by the cross-shaft, the traverse motion attained by respective components is
accordingly smaller.
7.5.6 Under winding

Conventional ring frames with manual doffing, doffer boys are taking care
of preserving threading for the next doff. However, modern high speed ring
frame, operating with auto doffing are provided with safety mechanism
for restarting, under winding. It refers the winding of few yarn coils (4–5),
loosely, either at the base of the bobbin (10–15 mm below the starting point)
or on spindle after the completion of cop building (Fig. 7.5 (i)). These loosely
under- wound coils slip past on the spindle at the point of doffing and preserve
threading for the next doff (Fig. 7.5 (ii)).
7.5.6.1 Significance of under winding

Retaining yarn threading between bobbin and front roller nip on doffing is
utmost important for smooth and quicker restarting for the next doff. Else
‘Gaiting-in’ and ‘piecing’ need to be done, to restart spinning. ‘Gaiting-in’ is
the process of winding few yarn coils at the base of bare bobbin on winder.
Randomly selected full cop from the previous doff is used for the purpose.
The wound yarn is utilized for manual piecing with drafted ribbon emerging
from front roller nip to start with the next doff. Hence successful piecing
demands 2–3 attempts to be performed, even by the skilled operator. This
head wise exercise increases unproductive time of the ring frame at the point
of restarting with new doff. The situation is more critical with longer ring
frame with higher number of working head. Under winding mechanism is
thereby designed to preserve threading and eliminate all such delay. Simply
by placing empty bobbin and bringing ring rail, lappet guide and balloon
control ring up to the starting position. Thus, next doff can be started within
few seconds to doffing. This reduces undue down time of the ring frame and
enhances its efficiency.
Apart from this, it also helps the operator on winder or next machine in
sequence to locate the yarn end easily due to back winding. This can save time
and increase efficiency of the next machine also. Back winding (Fig. 7.5 (i))
refers winding of the yarn from the tip of the bobbin to its base during ring rail
reversal for the under winding.
Figure 7.5 Significance of under winding
7.5.6.2 Sequence of under winding operations

i. Sensing end point of the cop building: Completion of cop building
is accessed by the sensor. It transmits the signal for activating under
winding mechanism. The sensor can be a mechanical device or
electric switch.
Resuming under winding position: Ring rail gets continuous upward
ii.
ascent during bobbin build up. It is thereby reaches at the top most
position at the end of bobbin build up. Under winding is carried out
near about the base of the bobbin, thereby ring rail which born yarn
guides for winding (travellers), is reversed and also dropped below
the starting position.
iii. Under winding: Only 4–5 coils to be laid loosely at the base of
the bobbin for the purpose. Half the rotation of the driving wheel
is enough to perform this job for its approx., 10:1 ratio with driven
wharve diameter. Thereby once the ring rail gets reversed; there is
no need to drive the spindle later on. So, the power supply of the
motor should cut off immediately once ring rail occupies the under
winding position. Hence spindles are driven at high speed (25,000
rpm), residual rotations of driver wheels are quite high enough before
resuming steady state condition on switching off the power supply.
Brake must be applied along with switching off the power supply to
the main shaft of the machine. This brings driving wheel to steady
state condition within half of its revolution. This is enough to lay
reserve coil bunch, otherwise increases hard waste unnecessarily by
laying more number of coils.
7.5.6.3 Types of under winding mechanism

Based on the working principle it can be divided into two categories: (i)
Manual mode and (ii) Automatic mode.
Manual mode: Conventional ring frame like Saco-lowel has a manual
mode to perform this task. End point of doff is judged manually. Interlinked
ring rail, lappet guides and balloon control rings are lowered down from
their top most position to under winding position manually by pressing the
foot pedal fitted on the common cross-shaft. Foot pedal is locked at under
winding position in the slot, power is turned off and brake is applied by the
operator. The residual rotations of the driving wheel are enough to lay desired
under winding coils. Mechanism is simple but operator bias and thereby less
accurate due to associated errors of manual handling.
Automatic mode: Manual tasks are replaced with electrical switches and
relays to make it more accurate and fast on modern high speed ring frame.
LMW LG5/1 ring frame is equipped with automatic mode of under winding.
Hence rest of the cop building mechanisms are discussed in its reference,
it thereby becomes easy to correlate automatic mode of under winding
mechanism incorporated on it.
Switching traverses during bobbin build up, continuously ascent ring rail
(Fig. 7.3). So, at the end of doff, ring rail resumes top most position (Fig. 7.5).
Layering traverse cam is driven via worm and worm wheel from the main
gearing. The driver pin/s provided on the worm wheel operates advancement
ratchet wheel and thereby rotates tape wind up drum in anticlockwise direction
throughout the cop build up. This shortens the tape length between builder
arm pulley and guide pulley. These anticlockwise turns are also earned by
under winding cam, mounted on take up drum shaft. It is fastened in such a
way that its stroke (larger throw) is off set from the sensor switch b26, in the
beginning of doff. Angular distance between larger cam stroke and switch
is set according to time required for complete cop building before initiating
under winding. It is mainly affected by yarn count, as rate of bobbin diameter
build up varies with yarn count. Wider difference is kept for finer count owing
to its slower build up rate and vice versa.
Two basic conditions must be fulfilled to start with under winding. They
are:
i. Ring rail and anti-balloon rings must occupy under winding position.
ii. Simultaneously lappet guide must resume top most position as well
as get tilted for the ease of doffing.
They are achieved by unlocking the respective parts from their normal
working position by releasing related limit switch (here, b26) on the completion
of cop winding. Also signal must be send to actuate various limit switches
(bxx), contactors with timers (delay switches, dxx) and electromagnetic solenoid
valves (sxx) operated pneumatic pistons (pxx) to accomplish under winding as
per the scheduled operating sequence.
Under winding sequence on LMW G5/1 ring frame

Once doff gets ready, the stroke of under winding cam set in such a way that
it presses the switch b26, coming in its way. Switch b26 on getting pressed
initiates under winding via multiple actions;
1. Declutching normal drive to the ring rail: Switch b40 is placed below
the builder cam. Although it is pressed by the cam in each rotation,
remains de-energized and not able to actuate solenoid S7 connected
with it. It gets energized on pressing by cam, only when switch b26
gets actuated by under winding cam, on the completion of doff. It
sends signal to solenoid S7 and actuates piston P7. Piston disengages
the clutch on 39T worm wheel shaft via link and lever connection.
This makes tape wind up pulley, free to rotate in reverse (clockwise)
direction under the influence of heavy ring rail weight. Thus tape
length wound during switching traverse, gets released and ring rail
lowers down to the starting position. Reversal/ring balancing spring
(buffer spring) gets tighten during upward displacement of ring rail.
This torque of the spring also helps ring rail in reversal on the release
of the clutch (Fig. 7.6).
Figure 7.6 Declutching normal drive to the ring

...Under winding mechanism on LMW LG5/1
Dropping the ring rail at under winding position: Switch b40 on

2.
getting energized actuates solenoid S3. This in turns operated piston
P3 and drops the toggle lever, releases extra tape length. Thereby ring
rail can drop below the starting position. Its further drop is suspended
by buffer spring cushion (Fig. 7.7).
Back winding: During downward displacement of ring rail switch b25
3.
gets pressed. It switch off solenoid S26 and turns motor to the slowest
speed for performing task of back winding. The lowering speed of
the ring rail is controlled by the damping cylinder (Figs. (7.7–7.8)).
It provides hydraulic cushion to avoid jerky downward movement of
the ring rail and prevents end break during back winding. The number
of back winding turns decides speed of ring rail during its downward
descend. It moves slowly for higher number of back winding turns
and fast for lesser turns.
Figure 7.7 Dropping ring rail to under winding position

Damping cylinder is provided with scale engraved with alphabets

A-B-C-D-E at the bottom end and twist value in twist per inch or
twists per 100 m at the rear end. Initial calibration is done by fixing
flat key in a vertical position and then setting pointer on ‘C’. This can
fixed angle between pointer axis and flat key axis. So, further change
related with twist level can only change position of pointer and not
an angle. Front roller delivery speed is constant, thus reversal rate
of ring rail defines the backwind coils laid on the bobbin. Pointer
is set to position ‘D’ or ‘E’, while working with higher twist level.
This gives faster oil flow for absorbing more jerks due to faster ring
rail movement and laying less number of back wind coils. Similarly
pointer setting on ‘A’ or ‘B’ is used while working with low twist
level. This gives slower oil flow for absorbing less jerks due to
comparatively slower ring rail movement and laying more number of
back wind coils. The ring frame provided with auto doffing, steeper
back wind is done. This requires additional acceleration of ring rail
movement in the lower third of the cop. The pipe with stop cock is
provided for the purpose on the damping cylinder (Fig. 7.8).
Figure 7.8 Hydraulic damping arrangement for ring rail reversal

Cut off the drive and laying under winding coils: Switch b40 on
5.
getting energized also sends a signal to actuate relay d27. However, it
gets actuated 1–20 seconds after receiving the signal. Its function is
to stop the main motor and fan motor, and also actuate brake. Cutting
off main drive along with application of brake can bring machine
instantaneously to the steady state but after the set delay. Duration
of delay purely depends upon the yarn count, twist and number of
under winding coils desire. Hence front roller speed is low for higher
twist. So, for the given number of under winding coils, timer of delay
is kept more. Similarly for finer count front roller speed is more, so
duration of delay is short. Thus it gives an enough time to the front
roller for delivering yarn length required to wind desired number of
under winding coils before declutching main drive. According to set
delay time spindles also continue rotations to build up require under
winding layer density before getting stop. Stoppage of suction fan

makes pneumafil system inactive momentarily for under winding.
Preparing lappet guides and ABC-rings for under winding: Actuation
6.
of b40 energized solenoid S6 and thereby piston P6. It lifts anti-balloon
rings slightly upward for unlocking its drive from the ring rail. This
movement presses switch b36 and turns off solenoid S6, permits anti-
balloon rings to fall down to under winding position along with ring
rail, lifting lappet guides at the top most tilted position. If brake
slips due to any mechanical limitations creates havoc in performing
rest of the under winding functions. So, relay d24 timer is actuated
simultaneously. It gives delay in unlocking of anti-balloon rings
(Fig. 7.9). Once anti-balloon rings resumes under winding position
actuates solenoid S8 and thereby piston P8. It tilts lappet guides at 90
degree for the ease of doffing.
Figure 7.9 Unlocking ABC-ring

Restoring position of ring rail: The moment switch b26 is pressed and
6.
connected to relay switch b40, the same time it also gets connected
with relay d23. But it gets actuated after time lag of 1–5 seconds
from the point of receiving signal. The function of the relay d23 is to
re-engage the clutch by turning off solenoid S7 and timer d27 for the
next doff and restore ring rail back to the starting position (Fig. 7.8).
Figure 7.10 Restoring position of ring rail

Long snarl removal: Ring rail after under winding moves back to
7.
the starting position. This makes yarn between front roller nip and
ring-traveller slack. In addition to this restarting of the motor operates
spindles first but takes a time to operate font roller (approx. 4 seconds)
depending on the length of gear train involved in the drive. As a result
of this the slacken length gets over twisted by the spindle rotations
occurs before getting new delivery length from the front roller.
This over twisted length has a tendency to snarl and likely to cause
multiple end break at the beginning of doff. Piston P1 is provided to
remove this snarl by giving short upward stroke to the lappet guides
in the beginning of doff for taking up the slackness and then descend
back to the starting position during winding (Fig. 7.11).
Figure 7.11 Long snarl removal

Actuation of delay drafting: Early rotation of the spindle allows this

8.
slack or snarl yarn to be get wound on the bobbin first before actual
commencement of spinning (drafting and twisting). This phenomenon
of preventing multiple end breaks in the beginning of doff is referred
as delayed drafting. Timer d23 delays clutching of drafting system
operation and runs the motor at slow speed up to delay drafting gets
over. This slow speed winding also helps in preventing end down
during winding comparatively weaker snarl.
Short snarl removal mechanism: Snarl formation can also takes place
9.
whenever machine drive is cut off apart from ON-Winding. Here ON-
Winding refers winding on new bobbin after completion of doffing.
This snarl formation is again attributed to delay drafting sequence

only. Due to any reason when machine drive is cut off, solenoid S2
and thereby piston P2 also get de-energized. They are responsible for
keeping ring rail in a lifted position. So, ring rail lowers down and
eliminates short snarl.
7.5.7 Further developments

Under winding is carried out on middle age ring frames for retaining the
threading for the next doff. The yarn need to wind several times around
the lower end of the spindle to hold it in the spinning position at the time
of doffing. After doffing gets over, this bunch of yarn sliced away from
the spindle by sharp cutter manually at a regular interval of time. Labour
uses a simple metallic cutter for the purpose. The yarn is reduced in small
pieces and then scattered on the floor. Apart from addition to hard waste,
the practice followed adversely affects housekeeping, liberates fly and also
prone to damage spindle surface by unskilled operation of the labour. Even
restarting the machine after doffing as mentioned above forms the snarl and
often cause multiple ends down. The situation is somewhat handled well with
the provision of snarl removal as an integral part of electronically controlled
under winding mechanism in comparison to its manual mode.
In order to address fly problem created due to manual removal system
of under winding coils, Marzoli has introduced an overhead cleaner with a
positive suction unit, viz. a wonder cleaner. It perfectly removes the under
winding of yarn, once the ring rail reaches a minimum height. The blower
pushes cutter against the spindle. It cuts and collects the under wind yarn coils
from every spindle instead of just cut and scatter them in the room as per the
manual practices. After the cleaning is performed, the suction activity remains
idle. The spindle cleaner is used with the blower only between doffing cycles.
This solution is precise enough for coarser yarn and can be well implemented
for medium and fine yarn. However it is not offering any solution to the
problem of snarl formation and thereby multiple end down on restarting a
new doff. They are still stand still.
Rieter has introduced the arrangement of SERVO-grip in replacement of
under winding on its G33 and G35 models. In this system, doffing of ring cops
is carried out without the under winding threads. However, threading for the
next doff is well retained by a patented crown. It is an added component of
the spindle. It is having the shape of pineapple slice, located just beneath the
bottom end of the bobbin on the spindle (Fig. 7.12). Just like clutch, it gets
open on receiving signal from electrical sensor and while the spindle is still
revolving slowly at the completion of doff. The yarn gets inserted in the open
crown and the crown gets closed afterward. When the cop is replaced, the
length of the yarn remains firmly clamped by the teeth of crown, eliminating
need of piecing on restarting the machine. Even the small loop of yarn caught
by crown gets released on its reopening for the next cycle. This also eliminates
need for cutting the yarn coils as in the previous case, responsible for the fly
generation. Thus the system has offered a better solution in terms of saving
labour power, damage to the spindle on cutting and generation of hard waste
along with better housekeeping.
Figure 7.12 Servo-grip on rieter G 35
7.6 References
4. Klein W. (1987). ‘The Manual of Textile technology: Vol. I – The Technology of Short
- Yarn Manufacture - II, [Accessed on 30 August 2014].
6. http://www.rieter.com/en/rikipedia/articles/spinning.../builder-motion, [Accessed on
30 August 2014].
8
Doffing
Abstract: Doffing deals with the replacement of cop by empty bobbin tubes to
restart with new doff. Classical ring spinning was labour intensive system and
thereby this job was performed by a team of unskilled doffer boys. However,
it was full of human error and operating with low working efficiency. Thereby
manual practice of doffing is discontinued on modern, long and high speed running
ring frames now a days. Electronically controlled robotic arms auto doffing has
replaced this labour compliment from the production course. This has assured
product quality at a much higher working efficiency, but at some additional cost.
A brief review of this entire changeover is elaborated stepwise in this chapter.
Key words: Cop, bobbin tube, doff, labour, doffer boys, efficiency, conveyor belt,
doffing rail, gripper, doffer rail
8.1 Introduction
Once the cop gets ready, it needs to be replaced by empty bobbin tubes to
restart with new doff. The entire exercise refers as doffing. Classical system
was labour intensive as many unskilled doffer boys were involved in this
exercise and machine remains production less for the time being. It was not a
good practice in terms of quality and economy of the product. So, this practice
of doffing is discontinued on long and high speed running ring frames now-
a-days. Electronically controlled robotic arms; auto doffing has replaced this
labour compliment from the production course. Thereby assured quality along
with desired productivity but at some additional cost. A brief review of this
entire changeover is elaborated stepwise in this chapter.
8.2 Doffing
Once the cop is ready it needs to be replaced by the empty one, known as
doffing. The capacity of full ring cop ranges between 30 g and 100 g of yarn,
depending on yarn count spun and size of the bobbin used. Nevertheless, it
takes 1–30 hours to fill it. Both the figures purely dependent on the type of
yarn spun. Doffing can be carried out manually (old) or mechanically (new)
after under winding is over.
8.3 Types of doffing

Doffing can be categorized into two basic groups: manual doffing and auto
doffing. As the name suggests the former one deals with labour to carry out
doffing, whereas later one depends on electronically controlled mechanisms.
8.3.1 Manual doffing

Doffing was performed only by hand on conventional slow speed ring frame
with less number of spindles (440–840). It is still performed manually in the
labour intensive countries with low wage levels. Operatives performing this
job are normally unskilled persons, referred as doffer boys. They grasp the full
cop with their left hand, lift it off the spindle and replace it on the spindle with
an empty tube in their right hand before the thread could break between the cop
and the spindle. This exercise is done spindle by spindle. Simultaneously they
are pushing two boxes with their knee along the longitudinal rails attached to
the machines. One of these boxes would contain the empty tubes; the full cops
would be placed in the other (Fig. 8.1).
Figure 8.1 Steps followed in manual doffing

Doffing 145
Doffing would be performed by groups in so called doffing teams, with

a specific section of the whole machine always being allocated to each
operative. Since it is a monotonous job, composed off very few actions, need
to be performed very quickly and constantly repeated, in a slightly slouching
posture. The limited capacity of the cop compels frequent doffing cycles to
be performed by the team. So, it is an unattractive job, and also becomes
very difficult to find personnel for this in industrialized countries. However,
manual doffing also has the advantage that the doffing team represents a
personnel reserve that is available at any time.
8.3.2 Automatic doffing

Modern ring frames are operating at high speed and provided with 2–3 times
more number of spindles. Both the factors demands replacement of slow and
erroneous manual doffing. Auto doffing offers faster replacement with proper
material handling along with significantly reduced unproductive down time
of speedy machine. All together assures precision of quality and economy of
the outgoing product. So, modern high speed longer ring frames are always
equipped with auto doffing system. Even with manual doffing systems the
process is interrupted once or twice for tours of inspection. Personnel need
to check that the process is proceeding correctly, and especially to ensure
that tubes have been fitted everywhere and are not jammed. These tours
of inspection are no longer necessary on good modern doffing systems,
since each spinning position is continuously monitored during doffing, and
collisions between tubes and spindles or cops are therefore impossible.
A distinction is made between two groups of auto doffed ring frames:
• Stationary systems integrated in each ring spinning machine, and
• Travelling carriage systems which can serve several machines.
Stationary auto doffing system: It is used popularly. All the cops are doffed
simultaneously from the machine with stationary systems, so less liable to
cause fault. Whereas, mobile systems usually feature individual doffing, often
also doffing in groups. Thereby they are somewhat susceptible to faults and
require considerable maintenance effort. A stationary system used on modern
ring frame is described below as an example.
8.4 Basic working elements of auto doffing

All the operations required for doffing are performed fully automatically here.
This demands provision of mechanical tool for replacing labour compliment
(Fig. 8.2). They are listed as follows;
Figure 8.2 Basic working elements of auto doffing system
i. A conveyor belt: It is equipped with discs to hold empty tubes (or

full cops), or a conveying mechanism with support discs arranged
one behind the other on narrow rails for pushing the discs along the
machine. In both cases the discs serve to convey the tubes prior to
doffing and the cops after doffing.
ii. A doffing rail: It is also extended along the entire length of the
machine, equipped with pegs which engage with the tubes (Zinser) or
collars (Rieter) to grip the outside of the tubes and cops.
iii. A system of lifting levers: It is usually in the form of tongs, to raise
and lower the rail and swivel it in and out.
iv. A tube preparation and creeling device: It is provided at the end of
the machine.
v. A cop storage device: It is also given at the end of the machine, or a
cop transfer unit to a directly connected winder.
Doffing 147
8.5 Doffing preparation

This refers special preparation of tubes at the tube loading station. Conveyor
belt starts to move along and under the loading unit some time before the
cops are full. In the process the tubes supplied in tube boxes are inserted on
the pegs of the conveyor belt so that every other peg is unoccupied. These
pegs later accommodate the full cops. During this operation the conveyor belt
moves slowly into its working position, until an empty tube and an empty peg
are positioned in front of each spindle.
8.6 Doffing cycle

The entire doffing process observes following steps (Fig. 8.3):
1. The doffing system observes idle condition as long as the cop gets
build up.
2. When the cop gets ready or fully wound, lever system comes into
action. It moves out with doffer rail and raises it to upper most
position.
3. After reaching their uppermost position the rods retract again. This
movement brings the rail positioned right over the cops. Then it is
lowered, until the pegs engage in the tubes of cops. Instead of pegs, the
cops can also be gripped by collars which enclose the cops. Gripping
and holding are affected by inflating the pegs or collars, or by means
of tubes. The adoption of method varies as per manufacturer.
4. Once the cops are gripped, doffer rail is raised again, but now with the
full cops. The system now deposits the collected bobbins on conveyer
belt. In this course, the rods are raised to lift the cops off the spindles,
swings out, lower the rail and move it over conveyor belt. The cops
are then seated on the belt. The compressed air is then discharged and
the cops are released from the grip.
5. After transferring full cops to conveyor belt, doffer rail still remains
over it, but rises slightly. Then the conveyor belt moves half spacing
forward so that the empty tubes reach a point exactly under the pegs
on the rail. Now the rail lowers again and compressed air fed in.
Inflated pegs engage in the empty tubes and hold them firmly.
6. The lever system extends again, to raise the doffer rail in the similar
fashion, but now with empty tubes for creeling. The raised rail moves
in over the spindles and then lowers with tubes onto the spindles.
Tubes are then pressed on spindles firmly. Once again the discharge
of compressed air releases the tubes.
Doffing 149
Figure 8.3 Auto doffing cycle
7. After doffing gets completed, the doffer returns to its idle position
below the spindles. At the same time the ring rail rises to the piecing
position, the balloon checking rings move upward and the yarn guide
flaps tilt downward. The machine starts.
8. The conveyor belt moves the doffed cops toward the end of the
machine, where they are discharged into transport trolleys or
individually transferred directly to the winder. Duration of automatic
doffing can be as short as 2 minutes.
During automatic doffing, the procedure is interrupted once or twice for
inspection. Correct functioning must be repeatedly checked; in particular,
care must be taken that tubes are donned on all spindles and are not jammed.
8.7 References
1. http://www.rieter.com/.../rikipedia/.../spinning.../automation/doffing/automatic
[Accessed on 25 August 2014].
9
Spinning geometry
Abstract: Spinning geometry refers the geometrical measures of machine parts

involved in spinning. They are defining different angles of deflection and path
lengths observed by fiber flux (yarn) during spinning. They have a significant
influence on the spinning process and thereby final yarn quality and cost. A
scientific approach is needed for optimizing all such parameters participating in
spinning geometry. This can help in sustaining not only spinning stability but also
assures yarn quality and economy.
Key words: Spinning geometry, spinning triangle, roller stand angle, angle of
wrap, angle of pull, winding on angle, balloon control ring, lappet guide, balloon
height, ring diameter, spindle height, package lift, front roller overhang, traveller
limiting speed
9.1 Introduction
Spinning geometry as the name suggests deals with the geometrical
measures of machine parts involved in spinning. They are defining different
angles of deflection and path lengths observed by fiber flux (yarn) during
spinning. They have a significant influence on the spinning process and
thereby final yarn quality and cost. A scientific approach is needed for
optimizing all such parameters participating in spinning geometry. This can
help in sustaining not only spinning stability but also assures yarn quality
and economy. Present chapter describes scientific relationship of various
spinning measures that may be constant or variable on the performance of
product yarn. Also their optimized values used in industrial practices as
on today are mentioned.
9.2 Spinning geometry

The fiber bundle passes through the drafting system, the yarn guide eyelet,
the balloon checking ring and the ring-traveller on the way from the roving
bobbin to the cop. These devices are arranged at different angles and distances
relative to each other, which results in different angles of deflection and paths.
Dimensions and guide angles, known collectively as spinning geometry
Spinning geometry 151
(Fig. 9.1), have a significant influence on the spinning process and final yarn
quality, and especially on:
• tension conditions
• ends down frequencies
• yarn irregularity
• fiber integration
• yarn hairiness
• incidence of fly
Figure 9.1 Spinning geometry
9.3 Important factors influencing spinning

geometry
Changing a spinning geometry parameter inevitably entails a change in all
other geometry parameters. They are:
(a) Spinning Triangle or Spinning Angle (γ)
(b) Angle of Wrap
(c) Roller stand angle (α)
(d) Lappet Eye position

(e) B.C.R.
(f) Ring Diameter
(g) Lift
Out of these, some parameters are constant for a given machine set up,
like roller stand angle, ring diameter, lift of the package, etc. Whereas some
are changing throughout the build-up of the bobbin, like angle of wrap, lappet
eye position, winding on angle, etc. Thus to ensure the performance of the
product yarn in terms of quality and economy, constant parameters need to
be optimized on scientific ground and variables need to be restricted within
preferable limits.
9.3.1 Spinning triangle

Twist in a yarn is generated at the traveller and travel against the direction of
yarn movement to the front roller. Twist must run back as close as possible to
the nip of the rollers, but it never penetrates completely to the nip because, after
leaving the rollers, the fibers first have to be diverted inwards and wrapped
around each other. There is always a triangular bundle of fibers without twist
at the exit of the rollers; this is called a spinning triangle. The twist moves
up until helix angle (θ) becomes equal to spinning angle (γ) of the spinning
triangle (Fig. 9.2 (i)). Most of the end breaks originate at this weak band
(spinning triangle) point. The yarn tension in the balloon can be transmitted
almost without obstruction as far as the drafting system. The length of the
spinning triangle depends upon the spinning geometry and the yarn twist level.
Influence of spinning triangle

(i) Working width: The greater the difference between drafting outlet
width (W) and spinning width (WS), the higher the loss of fibers (fly),
the greater the hairiness, and also adversely affects yarn structure.
Width WS should therefore be kept as close as possible to W (Fig. 9.2
(ii)).
(ii) The vertical length (L) of the spinning triangle: It depends mainly on
the twist. Higher yarn twist results in a short length (L1), but low yarn
twist in a longer spinning triangle length (L2). The greater spinning
triangle length (L2), bigger the spinning triangle form, bigger the weak
point and thus gives higher ends down rate. To keep the ends down
rate at the same level as for high-twist yarns, the yarn manufacturer
is forced to reduce yarn tension by lowering spindle speed for soft
twisted yarn (e.g. when spinning knitting yarns).
(iii) Spinning triangle: If it is too short, core fibers will be tied in without
tension. They can then absorb tensile forces in the axial direction only
to a limited extent, or only after the fibers in the outer layer have
been broken. Since the distribution of tension forces in the final yarn
is similarly uneven to that in the spinning triangle, the yarn shows
the same effect. When stress is applied to the yarn, the edge fibers
undergoes so much elongation from the very beginning that the
forces acting on them either cause the fibers to break, or in some cases
to slide apart before the loading forces can act on the neighboring
fibers inside the yarn. Fiber breaks proceed successively from outside
to inside. The yarn has low strength. Since the twist inserted in the
yarn is insufficient due to the uneven distribution of tension (the edge
fibers are ultimately wrapped around the core fibers), the negative
effect is reinforced. The yarn structure falls short of the optimum,
and most of the yarn quality parameters suffer more or less. Thus ring
spinning does not permit to work with too small triangle. Similarly
too big triangle represents longer weak band as explained above and
give rise higher end breaks.
It is therefore evident that as long as a significant spinning triangle
exists, perfect yarn structure with excellent spinning performance cannot
be achieved. It is necessary to find ways to reduce the size of the spinning
triangle drastically, and above all to reduce the width of the fiber flow exactly
to the width of the remaining spinning triangle. This has been achieved by so-
called compact spinning systems.
Length of the spinning triangle allows varying in a range between 2.5 mm
and 7 mm only but according to the machine design of different manufacturers.
9.3.2 Roller stand angle (α)

It is the angle formed by the yarn path through drafting system with the
horizontal plane of roller beam (Fig. 9.1). All the bottom rollers are housed
on roller stand, fitted on roller beam. Thereby the yarn path through drafting
system observes the same angle of inclination that of roller stand. So, it
represents the angle of inclination of roller stand with the horizontal plane of
roller beam on the other way round. It is interrelated with angle of wrap.
Lower roller stand angle (α = 30°), used on conventional ring frame,
results in bigger angle of wrap of yarn at front roller (θ), acts as a twist barrier
and results in poor twist flow. As a result of this it forms larger spinning
triangle. Thus offers all associated disadvantages of longer triangle mentioned
above. Modern ring frames are thereby designed with higher roller stand angle
(α = 60°). However, the value should not be increased beyond 60° otherwise
piecing becomes a problem.
9.3.3 Angle of Wrap (θ)

Angle of wrap refers the angle formed by the fibrous strand round the bottom
front roller before getting twisted (Fig. 9.2 (iii)). Machine design affects the
length of the spinning triangle through angle of wrap (θ) of the fiber-strand at
the front roller (Fig. 9.2(iii)). It acts as a twist barrier, thereby wider this angle,
the longer the spinning triangle forms with all its associated advantages and
disadvantages. The efforts are thereby made to work with smallest possible
angle of wrap. It is controlled by setting roller stand angle as mentioned in
Section 9.3.2. However, ideal zero angle of wrap is not achieved in practice
due to limitations of piecing.
Figure 9.2 Influence of spinning triangle

9.3.4 Front roller overhang (O)

The top roller is always shifted 3 to 6 mm forward compared to vertical
nip line of its associated bottom roller (Fig. 9.1). This is called top roller
overhang or deflection of the top front roller (O). This gives smoother running
and smaller spinning triangle.
Deflection of the top front roller (δ) offers following advantages:
(i) The extra guidance of the fibers by supporting the fibers without
clamping them,
(ii) The reduction of the abrupt bending-off of the edge fibers. Being
supported over a small surface area at the front roller up to lift-off
line (2), the fibers are gathered-in curving from the edge and tied in
firmly and regularly (Fig. 9.2 (ii)). Fiber loss is also reduced.
(iii) Reduces angle of wrap at front roller. At the reduced resistance,
twist will propagate closer to the front roller nip and forms smaller
spinning triangle. Thereby minimizes end breaks at the point of weak
band formation.
Although preferable, the overhang must not be made too large. Otherwise
the distance from the opening of the aprons to the roller nip line becomes too
long resulting in poorer fiber control and increased yarn irregularity.
9.3.5 Lappet eye position

The yarn section between drafting rollers and lappet form an angle with the
horizontal, known as spinning angle or angle of obliquity (γ). Hence lappet
guide ascends as well as traverses along with ring rail during bobbin build up,
the value of angle also changes with the position of the lappet.
Variation in the angle of obliquity ranges between γmax – γmin, according to
Fig. 9.3 (i), for top most and lower most positions of lappet eye.
The twist imparted by the spinning ring runs up to the nip of the drafting
rollers. The free run up of the twist is, however, hindered by the lappet. As
can be seen from Fig. 9.3 (ii),owing to the inclination of the yarn, and in
consequence of tensions To (spinning tension) and T (balloon tension), the
normal force N is developed. As a result of the inclination of the yarn, the
spinning tension To increases according to relationship
To = T. eµ [Eq. 9.1]
While the moment of friction produced by the normal force restricts the
free run up of the twist. The smaller the angle of obliquity of the yarn, the
more does this effect prevail. However at γ = π /2, the normal force becomes
zero and restriction to the free flow of the twist gets eliminated. But with
this set of spinning geometry piecing becomes difficult. So, value of angle of
obliquity is always kept below 90 degree.
According to relationship ‘Sin γ = b/a’ (Fig. 9.3 (ii)). The angle of
obliquity is at minimum,
• If the horizontal distance between the spindle shaft and the nip of the
drafting rollers (b) is the shortest, and
• If the vertical distance between the lappet and the drafting rollers (a)
is the longest.
The diminishing of measure ‘b’ is restricted by the position of the lappet,
ring rail, separators and balloon control rings. The constructional height of
the ring frame determines the increment of dimension ‘a’, first of all from the
point of view of the easy operation of the frame. The increment of dimension
‘h’ is also governed by the constructional height of the frame, i.e. by the
particular value of maximum balloon height (Hmax). Thus, taking into account
the above aspects, the most advantageous range of angle of obliquity for yarn
guiding can be determined.
On the upward ascend of lappet guide, value of ‘a’ reduces for constant
‘b’ as per machine set up used. This makes spinning triangle smaller and
wider angle of obliquity (γ2). Accordingly normal force (N), resisting twist
flow becomes smaller, so twist propagation to the fiber strand will be better.
The highest value γmax arises at the end of cop build up, permits to work at
smaller balloon height. Smaller balloon height Hmin allow spinning to continue
at low tension and thereby at reduced end break. The favourable situation will
be continued up to 35° spinning angle. Further rise in value causes increased
end down frequency due to poor yarn strength occurs at reduced orientation
while working with low spinning tension. Apart from this lappet guide exerts
braking effect on the pulsation of the balloon, which seldom rotates smoothly.
Continuous impacts and vibrations are arising due to traveller speed variation
during layering traverse. Balloon absorbs them and not allowed end to break.
But with smaller balloon formation, almost triangular balloon, at the tip of the
bobbin, this flexibility of dampening vibration diminishes results in excessive
end breaks.
Similarly the lowest position of lappet guide arises at the beginning of cop
build up. At this position, ‘a’ increases to ‘a + h’ for constant ‘b’ as per machine
set up used. Thus makes spinning triangle longer and angle of obliquity (γ1)
smaller. As a result, normal force ‘N’, resisting twist flow increases, so twist
propagation to the fiber strand will be poor. Formation of longer spinning
triangle or weak band along with higher spinning tension owing to bigger
balloon height accelerates end down frequency (Fig. 9.3 (i)). The favourable
spinning situation arises up to 15° spinning angle formed for the lower most
position of lappet guide. Going beyond this value spinning stability is not
achieved.
The distances measured from the spindle rail, and roller beam to the floor
(A and B) are dimensions which influence the total length of the yarn path on
the ring frame (Fig. 9.3 (i)). Both dimensions are governed by the conditions
of the easy service of the machine.
Figure 9.3 Influence of lappet eye position
9.3.6 Balloon control ring

Maximum balloon diameter develops at the beginning of the spinning
procedure. If the bobbin used is tall, than this height goes beyond the node
length (πP) and balloon gets collapse. Anti- balloon ring is then employed to
divide the large single balloon into two equal halves. This reduces balloon
height to the permissible level (<πP) and spinning stability can be attained.
Reduction in balloon height has also a direct impact on the spinning
tension. As yarn tension in the balloon is the tension, which finally penetrates
almost to the spinning triangle and is responsible for the greater part of the
thread breaks. It is reduced to a very small degree by the division of single
large balloon into two smaller ones. Thereby considerably reduces spinning
tension and end down frequency. However spinning at low tension adversely
affects fiber orientation in yarn matrix and results in yarn with low strength.
Even yarn hairiness gets increased due to continuous yarn rubbing with ring
surface.
Normally adopted anti-balloon ring setting is half of the balloon height.
LBCR = LB/2 [Eq. 9.2]
Here ‘LBCR’ represents a distance between ring and balloon checking ring
and ‘LB’ balloon height from ring.
9.3.7 Ring diameter (DR)

Ring diameter refers the measure of inner diameter of the ring. Its selection
depends on following factors:
(a) Yarn count
(b) Spindle speed, admissible from the point of view of the traveller
burning
(c) Ratio of package dimensions
Their interrelationship is shown in Eq. 9.1. Accordingly ring spinning
at a constant balloon height and spindle speed, yarn tension varies with yarn
count. Finer the yarn, metric count (Nm) value will be high and for rest of the
parameters being constant, yarn tension (Tx) will be less.
n2
Tx = 0.112 [Eq. 9.3]
N m × c2
Where, Tx is the vertical component of the yarn tension (g), n = traveller
(spindle) speed (10−3 min−1), c = coefficient of the centrifugal force (cm−1), and
Nm = metric count of the yarn.
Hence centrifugal force required for balloon formation depends on mass
of traveller (m), ring diameter (2R) and spindle speed. Thereby for known
yarn tension Tx and spindle speed (n), traveller weight or ring diameter
values can be altered for getting desired balloon size. It will allow spinning
to continue without causing balloon to interfere with rotating bobbin
encapsulated inside. Selection of traveller count must be done in accordance
to yarn count, otherwise results in either balloon collapse or traveller fly, if
used heavier or lighter respectively. Ring diameter is changed with respect to
yarn count for controlling yarn tension. Smaller diameter rings are used for
finer count and larger one for the coarser one. But it may result in packages of
disproportionally small diameter, and reaching the value taken for the ration
d/D becomes impossible under mill condition.
The ratio d/D is important for defining yarn tension required to rotate
the traveller against larger radial component of winding force (FW). Smaller
the ratio higher the stress involved liable to cause frequent end breaks. In
view of the above, in practice both traveller weight and ring diameter are to
be reduced. However, within the ranges of particular yarn counts, changing
the ring are to be avoided for controlling yarn tension, i.e. package density is
controlled by changing the traveller weight only. If ring diameter is changed
it can affect the following parameters also:
(i) Yarn content of the package – Rotating bobbin is encapsulated inside
the yarn balloon formed by the traveller racing on the ring. Enough clearance
must be kept between bobbin surface and revolving traveller especially at the
biggest diameter of bobbin. Full bobbin diameter is thereby restricted by the
ring diameter. Normally adopted relationship between full bobbin diameter
(df) and ring diameter (D) is as follows:
df mm = (D – 3) mm [Eq. 9.4]
Thus amount of yarn wound on the package is limited by its full bobbin
diameter. It is higher for bigger ring diameter, results in low doffing frequency
and thereby reduced downtime of the machine.
(ii) Spindle gauge – Spindle gauge represents the axial distance between
the neighbouring spindles. In order to prevent contacts between the balloons,
a distance of at least 24 cm is provided between the spindles. The possible
maximum balloon diameter is almost 2.5 times as large as the diameter of the
ring.
Accordingly, for a ring diameter of 48 mm, in case there is no contact
between the balloons, a spindle gauge of 120 mm is to be applied. From the
point of view of exploiting spindle capacity, this value still appears to be
too high. Generalizing rings with bigger diameter makes spindle mounting
accordingly wider spaced and increases spindle gauge. Bigger spindle
gauge allows less number of spindles (production unit) per machine to be
accommodated and reduces production per machine.
A further decrease in spindle gauge may be obtained by the use of
separators. They reduce balloon diameter without considerably increasing
yarn tension.
(iii) Production rate – Limiting speed of the traveller (π DRNT) is
dependent on the combination of ring-traveller used on a frame. Thus for a
given limiting speed of traveller, if ring diameter (DR) is large then traveller
speed (NT) will be less. Spindle speed is thus restricted to lower value. Hence
spindle speed determines production rate of the ring frame. Thus for the lower
allowable spindle speed production rate attained by ring frame is also low.
9.3.8 Winding on Angle (Ø)

It represents the measure of an angle formed between tangent drawn to yarn
path from traveller to bobbin and line passing from traveller to bobbin axis
(Fig. 4.8) It is also referred as angle of yarn pull (Ф) and evaluated by using
following relationship:
Sin Ø = dB/DR [Eq. 9.5]
It helps in identifying the desirable ratio of tube diameter (d) in accordance
with the spinning ring diameter (D), to attain highest spindle speed at the
lowest end breakage rate.
If ring diameter is increased by keeping identical bobbin diameter, angle
of pull (Ф) will be less. This makes axial component (F Cos Ø) higher, keeps
traveller pressed against ring surface firmly. Thereby yarn has to work more
to lift the traveller and rotate around ring for twisting with lower tangential
component (F Sin Ø). This induces more yarn tension and leads towards
increased end breaks.
The angle of pull (Ø) for smallest tube diameter (at the tip dH) should
not be reduced less than 23°. Normally employed angle of pull (Ø) is 25° to
27° with smallest bobbin diameter. The tube and ring diameters must have a
minimum ratio, between approx. 1:2 and 1:2.2, in order to ensure that the yarn
tension oscillations do not become too great.
9.3.9 Lift of the package (L)

Lift represents the admissible winding height of the tube. About 10 mm
allowance is given at the tip as well as base of the tube for preventing slough
off. Thus lift of the package is about 20 mm shorter than tube height (HT).
The most advantageous ratio between lift height and ring diameter often
seems to be problematic in ring spinning. Selection of these parameters must
be done in conjunction with each other to avoid production of disproportionate
package.
If the ring diameter compared to the lift is too small, then balloon
collapses may occur. The balloon height is too high for its diameter and this
implies considerable tension differences between winding on the cop base
and winding at the top. Apart from this larger variations in tube diameter also
leads to twist variations, count variations and higher end breaks occurs due to
continuous acceleration and deceleration of traveller speed.
On the other way excessive end break will occur if too large ring used
compared to the lift. This is due to abrupt rise in yarn tension due to bigger
diameter balloon formation. Separators need to be employed to control balloon
diameter in such case.
The normally adopted ratio of tube height to ring diameter HT/ DR is
0.2 to 0.225 for stable spinning situation. Use of anti-balloon ring becomes
mandatory, while working with longer lift package with preferable HT/ DR
ratio. Otherwise if Hmax is higher than node height (πP), balloon gets collapse
makes spinning impossible.
9.3.10 Other variables

Initial distance between lappet and spindle tip (LT)
The initial distance between the lappet and the spindle tip is given by the
condition. The condition deals with spinning at the smallest balloon height.
This happens when winding on the smallest bobbin diameter, tip of the cop.
It is mandatory that there should be no contact between the balloon and the
upper flange of the tube, although balloon formed at this end is the smallest.
Hence height of the balloon at this point responds to the distance between
lappet guide and spindle tip or bobbin tip. It should be optimized accordingly.
However, the above distance influences both, the yarn tension and the
constructional height of the ring frame. So, if it is chosen keeping into mind
second factor only, viz. as small as possible, then results in excessive end
breaks. This is mainly attributed to higher yarn stresses involved due to
formation of triangular balloon. The yarn, after the lappet, passes inside the
tangent of the balloon, thus for preventing contacts, the distance must be
adequately chosen.
LT = (2 × dH) + 5 mm [Eq. 9.6]
At least distance must be kept at the lowest position of lappet guide,
where dH represents tube diameter at the tip of the bobbin.
Ratio of tube outside diameter at top to ring diameter (dH/DR)

While spinning at the end of doff, the balloon should not clash with tube outer
surface diameter. The diameter of the balloon responds to ring diameter (DR).
So, the ratio of tube outside diameter at its tip to ring diameter dH/DR should
be adequately chosen. Otherwise results in excessive end breakage rate, either
due to higher yarn tension or balloon collapse. Normally ratio of 0.45 to 0.5
is kept.
Length of angle of wrap at front roller

As discussed in earlier section, angle of wrap at front roller acts as a twist
barrier. It cannot be made zero as ideally required, otherwise piecing is not
possible. So, normally kept shorter than the staple length of fiber in the
beginning of doff. It goes on changing with respect to lappet guide position.
9.4 References
Economics’, Taylor and Francis.
3. http://www.rieter.com/.../rikipedia/.../ring-spinning/.../spinning-geometry, [Accessed
on 12 July 2014].
– Yarn Manufacture II, [Accessed on 1 August 2014].
10
Yarn tension theory
Abstract: Ring spinning is always carried out under tension. This tension has
a positive impact on yarn strength due to improved fiber orientation in yarn
matrix. Even though preferable yarn tension need to be controlled or else results
in higher end breaks when exceeds yarn strength. This demands identification
of various ring spinning parameters in three main tension zones contributing to
yarn tension. Variables need to be optimized for varieties of yarn spun on a given
set up of machinery.
Key words: Traveller, yarn tension, winding, balloon, centrifugal force, resistance
force, mass of traveller, Coefficient of Friction, normal force, spinning tension,
yarn strength, Coriolis forces, air drag
10.1 Introduction
Ring spinning is always carried out under tension. This tension has a positive
impact on yarn strength due to improved fiber orientation in yarn matrix.
Even though preferable yarn tension need to be controlled or else results in
higher end breaks when exceeds yarn strength. This demands identification of
various ring spinning parameters in three main tension zones contributing to
yarn tension. Variables need to be optimized for varieties of yarn spun on a
given set up of machinery.
10.2 Yarn tension involved in ring spinning

Yarn tension and balloon geometry are two co-related phenomenon. Their basic
aim is to spin the yarn at optimized or minimum possible end breakage rate by
controlling yarn tension. Minimum viable tension must be maintained to carry
out spinning successfully. The aim for working under tension is different for
three main zones identified for stable spinning. They are distinguished based
on yarn tension requirements: Spinning zone Tension (FS), Ballooning Zone
Tension (FB) and Winding Zone Tension (FW) as given in Fig. 10.1 (i). Values
of these tensions are different but they are inter-related. They can result in
increased end breakage rate if not controlled properly.
Figure 10.1 Yarn tension in ring spinning
10.3 Need of yarn tension in different zones of ring

spinning
Tension involved in three zones of ring spinning differs in terms of its need
and magnitude. It is briefly summarizes below:
Spinning zone: It is the tension required for suitable conversion of drafted
strand to yarn between front roller and lappet guide. It means for imparting
desired fiber orientation before being twisted and ensures well packed yarn
structure. Thereby product yarn can achieve favourable strength – spinning–
tension relationship.
Balloon tension: It deals with the yarn tension desired to develop stable
balloon envelop. The balloon must be sufficiently large enough to avoid
interference with the rotating bobbin encapsulated inside. This is mandatory
Yarn tension theory 165
for stable spinning to prevent balloon collapse between lappet guide and
ring traveller. On the contrary the balloon should not be too large to cause
excessive end breaks due to higher balloon tension.
Winding tension: It is the yarn tension prevailing between traveller and
bobbin. It defines the compactness of wound package and thereby doffing
frequency.
10.4 Various forces acting on the traveller

In ring spinning, tension develops in the yarn mainly used to move the traveller
and the balloon length around the spindle axis, and to wind the yarn onto the
spinning bobbin. Work must be done against the frictional force of the ring
on the traveler and of the traveler on the yarn, as well as against the air drag
on the traveler and on the balloon length. This work should be added to that
needed to overcome the friction of the spindle bearings and the air drag on the
forming yarn package.
The following forces act on the traveller during its movement
(Fig. 10.1 (ii)):
1. The yarn tension directed yarn guide towards the ring (FN)
2. The winding tension directed towards the yarn package (Fw)
3. The centrifugal force acting on the traveller (FZ)
4. The weight of the traveller (Mg) acting downward, where M is the
mass of traveller
5. The reaction force substituting the constraint produced by the ring (FR)
Since it is a three-dimensional module of forces, plotting the axes x and
z of the co-ordinate system in the plane of the ring, the axis y will lie in the
rotation axis of the spindle. Be the traveller in its momentary position in the
point of intersection of the ring circumference, and the axis x. Furthermore, let
R be the reaction force produced by the ring. The reaction force R is thereby
composed of two forces:
(a) The friction force FR = µP of a sense contrary to the movement of the
traveller and falling in the direction of the tangent of the ring (where
µ is the coefficient of the friction between the ring and the traveller),
(b) The force P = FZ – FN, falling in the plane (XY) substituting the
support of the traveller, and directed to below the base plate (XZ).
The dynamic equilibrium condition of the traveller is that the sum of the
projection of all the forces is zero in the direction of all the three co-ordinate
axes. Here effect of air drag and Coriolis forces on yarn tension, since very
small ignored to avoid undue complication.
10.5 Mathematical expression for yarn tension

Yarn tension is a vector quantity and thereby its direction and magnitude both
are equally important. In order to optimize working tension in different zones
of ring spinning mathematical relationship among the various parameters
involved in the section is of utmost important.
Although, winding section comes last in the sequence of yarn production
process, it is the initializer of yarn tension development. Spindle rotation
makes the bobbin to pull the yarn for winding from the front roller nip.
Thus it develops yarn tension required to rotate freely hanging traveller on it
around the ring for the insertion of twist to the drafted strand delivered. Thus
propagation of yarn tension commence from winding zone to spinning zone.
Thereby mathematical derivation for the yarn tension expression prevailing in
different zones in the state of equilibrium of forces acting on the traveller at
the winding section is considered first in the sequence (Fig. 10.1 (ii)).
10.5.1 Winding zone tension (FW)

Winding force FW acts tangent to the circumference of the bobbin at winding
on angle ‘Ø’ with respect to line joining traveller and package center. Normal
force (FN) is the horizontal component of winding force (FW). It represents the
normal reaction force between ring and traveller. As shown in Fig. 10.1 (ii),
FN = FW Cos Ø [Eq. 10.1]
A tensile force (FT) arises from the winding tension of the yarn and always
acts at a tangent to the circumference of the cop. A frictional force (FR) acts
between the ring and the traveler. In the stationary state, i.e. with constant
traveler speed, this braking force (FR) is in equilibrium with the forward
component (FT) of the yarn winding tension (FW). Where,
FT = FW Sin Ø [Eq. 10.2]
In the state of equilibrium:
FR = FT = FW Sin Ø [Eq. 10.3]
Normal force (FN), pulling the traveller in the direction of the cop,
diminishes ring-traveller friction created due to ballooning FZ. Thereby net
force (P) by which the traveller pressed against ring surface is:
P = FZ – FN [Eq. 10.4]
dR
= M × × ω2 – F_w Cos Ø [Eq. 10.5]
2
Where M is the mass of traveller, dR is the ring diameter, ω is the angular
rotational speed of traveller.
ω = Nspindle × π /30 [Eq. 10.6]

Frictional resistance experienced by traveller experience during its
movement is represented by ‘P’. But coefficient of friction µ between ring and
traveller also affects these resultant forces. So, the frictional force FR arising
from these forces is equal to µP. Thus
FR = µ(FZ – FN) [Eq. 10.7]
According to Professor Krause (ETH, Zurich, 1968), under the state of an
equilibrium FT = FR; Where FT is the tangential force causes traveller to rotate.
Hence,
FT = FW Sin Ø [Eq. 10.2]
Substituting values from Eq. 10.3 and Eq. 10.7, it will become:
\ FW Sin Ø = µ (FZ – FN)
Based on Eq. 10.5 and Eq. 10.7, frictional force is:
 dR 
FR = µ  M × × ω2 − Fw cos ∅  [Eq. 10.8]
 2 
 dR 
\ Fw Sin Ø = µ  M × × ω2 − Fw cos ∅  [Eq. 10.3]
 2 
µMd R ω2
\ Fw (Sin Ø + μ Cos Ø) = [Eq. 10.9]
2(Sin ∅ + µCos ∅)
For µ being very small, ignoring 2µ Cos Ø.
µMd R (2πNs ) 2
Fw = [Eq. 10.10]
2(Sin ∅)
µMd R VL2
or Fw = [Eq. 10.11]
2Sin ∅.d R
Where, VL represents surface speed of the traveller.
Thus winding force FW changes in direct proportion to coefficient
of friction between yarn and traveller (µ), ring diameter (dR) and mass of
Traveller (M). It changes in square proportion to spindle speed (Ns), but in
indirect proportion to winding on angle (Ø).
10.5.2 Ballooning zone tension (FB)

Balloon zone tension (FB) represents the yarn tension due to balloon formation
between lappet guide and ring-traveller. Centrifugal force (FZ) caused on
balloon formation induces yarn tension which finally penetrates almost to the
spinning triangle and also responsible for most of the thread breaks in practice.
The yarn tension in this zone is mainly attributed to yarn pull which
makes the traveller, suspended on it, to rotate around the ring. Thus the
tension differs from the winding tension due to frictional contact made with
traveller on leaving the balloon and entering the winding section. It is reduced
to a very small degree by the diversion of the yarn at the thread guide. Thus,
winding tension get exceed by exponential component of the product of angle
of wrap at traveller θ and coefficient of friction between yarn and traveller (µ),
according to winding theory.
FW = FBeµθ [Eq. 10.12]
Where e is the base of natural logarithms.
Thus, FB = FW/eµθ
The value of angle of wrap changes with balloon size (Fig. 10.1 (iii)).
Thus, product eµθ not remains constant but also goes on changing. According
to Klein (1987), eµθ = 1.2 to 1.8. Taking the average eµθ = 1.5.
\ FW = 1.5FB [As, FB = FW/eµθ]
Substituting mathematical expression (Eq. 10.9) for yarn tension in
winding zone, the above expression will be:
FW µMd R ω2
FB = = [Eq. 10.13]
eµθ 2(Sin ∅ + µCos ∅).eµθ
Thus, balloon tension FB gets influenced by ring diameter, mass of
traveller, spindle speed, coefficient of friction between yarn and traveller and
winding on angle.
Yarn tension FB(max) at the point of maximum diameter in the balloon can
be derived approximately from the following formula given by Professor
Krause (1959):
FB(max) = k × ωL2 × H2 × σ [Eq. 10.14]
Where, ωL is the angular velocity of the traveler, H is the height of the
balloon, σ is the specific mass of the yarn, i.e. (yarn mass/yarn length) ≈ tex,
and k is a constant.
Thus, for a given yarn count, the yarn tension in the balloon is strongly
dependent upon the traveler speed and the height of the balloon. Thereby high
traveler speeds, and greater balloon heights, lead to very high yarn tensions in
the balloon.
The, major influencing factor for balloon zone tension (FB) is balloon
dimensions itself, viz., diameter and height. So, it can be varied by changing:
• Traveller speed/spindle speed for the given count. As it defines bulge
of the balloon and
• Lift of the package, as it defines height of the balloon.
10.5.3 Spinning zone tension (FS)

Lappet guide is located at the tip of the balloon and twist propagates from
bottom to top. Thereby spinning tension is always lower than balloon tension
by half the centrifugal force. Assuming lappet guide is not acting as a twist
barrier and allows twist to flow fully up to the nip of front roller. Then,
FB = FS – ½mRω2 [Eq. 10.15]
Where, m = yarn fineness in tex, R is the ring radius in mm, and ω =
Angular velocity of the traveller. Substituting mathematical expressions for
FB, it will take the shape:
µMd R ω2 1
FS = µθ
− mRω2 [Eq. 10.16]
2(Sin ∅ − µCos ∅).e 2
Thus spinning tension FS gets influenced by ring diameter, mass of
traveller, spindle speed, coefficient of friction between yarn and traveller and
winding on angle.
Summarizing the discussion, yarn tension during spinning for a given
yarn count (m) depends on
• Ring diameter
• Mass of traveller
• Spindle speed/traveller speed in square proportion
• Air resistance/air drag
• Coriolis forces
• Balloon height
• Package diameter
• Angle of yarn passage through traveller
• Winding on angle
Parameters like ring diameter, bobbin dimensions, mass of traveller and
spindle speed remains constant for the selected yarn count. But parameters
like balloon height, winding on diameter, air drag, Coriolis forces, angle of
yarn passage through traveller etc. go on changing with the cop build up. They
need to be given due consideration for spinning at constant yarn tension in
order to attain precision in product yarn quality.
10.6 References
1. Chattopadhyay R. (2000). ‘Yarn Tension in ring spinning’, NCUTE – Pilot Programme
on Ring spinning, Doubling and Twisting, NCUTE Delhi, pp. 101–109.
4. Stalder H. (1994). ‘Increasing ring spindle speed in consideration of yarn quality and
running condition’ Melliand English, 7–8, E 140.
5. https://www.scribd.com/.../yarn-tension-and-balloon-geometry-in-ring-spinning,
[Accessed on 20 August 2014]
6. https://nptel.ac.in/courses/116102038/24, Yarn Tension in Ring Spinning – nptel
11
Parameters influencing yarn tension during spinning
Abstract: Ring frame holds major share in yarn cost. Apart from the raw material
cost the major share to yarn cost is coming from the power cost. Out of the
total power consumption of spinning process, ring frame consumes maximum
power in comparison to rest of the spinning sections. Spindle drive absorbs major
share of energy allotted to ring frame. So, proper utilization of this larger energy
share for getting desired yarn quality at an economical rate becomes an utmost
important. The variables influencing yarn tension during spinning and thereby
added power consumption need to be identified and rectified accordingly.
Key words: Energy cost, spindle drive, traveller mass, Angle of wrap at traveller,
triangular balloon, Coriolis forces, air drag, balloon height, Angle of wind
11.1 Introduction
Ring frame holds major share in yarn cost. Apart from the raw material cost
the major share to yarn cost is coming from the power cost. Again ring frame
consumes maximum power in comparison to rest of the spinning sections and
in that spindle drive absorbs major share of energy. So, proper utilization of
this larger energy share for getting desired yarn quality at an economical rate
becomes an utmost important. The variables influencing yarn tension during
spinning and thereby added power consumption need to be identified and
rectified accordingly.
11.2 Parameters influencing yarn tension during

spinning
According to the cost structure of the spinning mill given by Rieter, ring frame
holds 60% share. As per the bifurcation of production costs in a spinning mill,
20% of the total falls under the heading “energy”. Out of total energy cost
of spinning about two thirds are incurred only in the ring spinning section.
The power consumption of ring frame is mainly utilized in drive given to
drafting arrangement, spindles and builder mechanism. Hence the major
share of about 65–70% energy utilized by ring frame is absorbed for driving
spindles only. Thereby proper utilization of this larger energy share for getting
desired quality product at an economical rate becomes an utmost important.

Technological problems associated with machine drive need to be resolved by
identifying the variables influencing yarn tension during spinning.
Tension variations are introduced during cop build up, due to change in
the important parameters related with yarn tension in different zones. As per
discussed in previous chapter, the parameters identified as follows:
1. Traveller mass
2. Air resistance/Air drag
3. Coriolis forces
4. Balloon height
5. Angle of yarn passage through traveller
6. Winding on angle
11.2.1 Mass of the traveller

The high speed rotational motion of yarn, when taken off a package over-
end, results in generation of centrifugal force and forms the envelope of the
yarn path between yarn guide to traveller. This envelop of yarn is known
as balloon. The dimensions of the balloon, its height and diameter, specify
the envelope of the yarn path and greatly influence yarn tension in spinning
section. Coriolis force and the air drag also have an effect on yarn tension, but
it is small in comparison with that of the centrifugal force.
Hence,
Centrifugal force, F = MRω2 [Eq. 11.1]
Thus centrifugal force (F) is affected by the mass of traveller (M), radius
of the ring (R) and rotational speed of traveller (ω). Since traveller speed is
almost same as the spindle speed, it is normally replaced by the rotational
spindle speed (n) for practical purpose. It is never advisable to frequently
change ring diameter. Also, spindle speed is set optimum, as it defines
production rate. Thus, at the point of spinning, two main parameters out of
three influencing centrifugal force or balloon dimensions are always constant.
Balloon size is thereby purely influenced or controlled by the traveller mass
(Figs. 11.1 (a)).
Traveller acts as a tensioner during spinning as well as winding. So,
change in its mass can vary balloon shape as well as compactness of bobbin.
Accordingly, if heavier traveller is used, yarn bulges less and if not interfering
with encapsulated balloon than spinning and winding will be carried out under
more tension. Higher spinning tension improves fiber orientation and thereby
results in increased yarn strength. Similarly higher winding tension results
Parameters influencing yarn tension during spinning 173
in compact package formation and thereby enhances machine efficiency due

to increased yarn content of the package. On the contrary it reduces angle of
wrap at lappet guide and traveller (θ1 and θ2). Reduction in the angle values,
increases lappet-yarn and yarn-traveller contact. The increased frictional
contact of yarn at lappet guide offers more resistance to twist flow and brings
about higher twist variations. Whereas increased friction between yarn and
traveller, results in hairy yarn.
Reduced spinning tension with lighter traveller spreads balloon more at
the center, increases balloon diameter. It is better for enhoused bobbin, not
interfere with it and prevents balloon collapse. But at the same time it adds
the fear of multiple end break due to balloon slashing. Less tension during
spinning and winding also adversely affects yarn strength and machine
efficiency. The soft package so formed is more prone to slough off, further
reduces machine efficiency as well as hard waste. However bigger angle of
wrap formed at lappet guide and traveller (θ1 and θ2), provides ease of passage
at both the points. Produces yarn with less twist variations and hairiness.
Selection of traveller mass thereby should be done in a manner to avail
spinning stability by avoiding balloon collapse. Same time it should produce
compact package, easy to handle and unwind. Moderate angle of wrap
formed at lappet guide and traveller (θ1 and θ2), for ease of yarn passage. If
the choice is left between light and heavier traveller, than later one is always
preferred.
11.2.2 Air drag

Air-drag on a ballooning yarn refers to the air resistance offered to the whirling
outline formed by the rotating yarn under the influence of the centrifugal
force. This affects balloon shape by the deviation of yarn path. As a result,
greater work to be done to rotate the yarn increases yarn tension and likely
to cause ends-down (yarn breakage). Thus it affects energy consumption and
yarn productivity in ring spinning.
During ballooning yarn are laying in the axial plane; all points on the yarn
lie in the same plane as the axis. But the closer examination of the balloon,
by using stroboscope or high speed photography shows that the yarn does not
lie in a straight line but resumes a curvature (Fig. 11.1 (b)). The yarn forms
a curved line behind the traveller with the end near the traveller leading and
part of the yarn in the balloon trailing. This is due to the air resistance to the
rotation of yarn and the effect is referred as ‘air drag’. It depends upon the
length of the yarn in the balloon and yarn count. Longer the length and coarser
the count, higher is the air drag.
Figure 11.1 (a–b) Parameters influencing yarn tension during spinning
Air drag also comes into picture in the winding region, between traveller
and bobbin. If the yarn is assumed weightless, undergoing no air drag and
by neglecting the yarn axial velocity, the yarn would lie in a straight line in
winding zone (Fig. 11.1 (c)). But actually resumes curved line. Thereby to
overcome the effect of air drag, there must be a net tangential force on each
element in the direction of rotation. The moment of the tangential component
of tension increases from traveller to package, increases yarn tension.
Hence effect of air drag is complex and as mentioned before having less
influence on yarn tensioned detailed mathematical analysis is avoided.
Figure 11.1 (c–d) Parameters influencing yarn tension during spinning
11.2.3 Coriolis forces

The balloon radius is maximum at the middle and reduces on either of side.
When a yarn element moves through the balloon, it has to move from the
smaller radius to the larger radius. It must therefore have been acted on the
elements by a force in the direction of rotation. This force is referred as

Coriolis force, associated with radial velocity of rotation when element is
moving outwards and in the opposite direction when it is rotating inwards
(Fig. 11.1 (d)).
The effect of the Coriolis force has often been omitted in theories of yarn
spinning because its effect is considered small in relation to the centrifugal
force.
11.2.4 Balloon height

The balloon height influences spinning tension greatly. The tension level
increases as the balloon height increases. Hence the balloon height is not
remaining constant throughout the cop build up as ring rail performs layering
traverse and switching traverse, for winding yarn over the entire length of the
bobbin. Initially with new doff, balloon height is maximum gives highest yarn
tension. With upward movement of ring rail, balloon height goes on reducing,
also proportionately reduces yarn tension.
Again, spinning tension increases when the balloon height becomes too
short. Presumably because:
(1) The balloon becomes a cone and its expansion prevents adjusting
action even by the instantaneous tension variation of yarn. As, conical
balloon is not able to act as a flexible buffer to absorb the shocks
caused due to continuous acceleration and deceleration of traveller
during layering traverse.
(2) When the balloon becomes a cone, the traveller inclines to the interior.
(3) Besides, spinning tension at the end of winding, more than at any
other time is affected by smallest winding on diameter (Fig. 11.1
(e)).
11.2.5 Angle of yarn passage through traveller

It refers the angle formed by the yarn at the entry point to traveller with
winding (horizontal) axis. It changes with the shape of the balloon. Larger
diameter balloon forms bigger angle of wrap and offers less yarn tension due
to reduced friction. Thereby yarn tension due to angle of wrap is less at the
beginning of doff as compared to end of doff (Fig. 11.1 (f)).
Conical balloon formation at the end of doff, when winding on a smallest
bobbin diameter. This forms smaller angle of wrap, increases abrasion between
yarn and traveller. Results in higher yarn hairiness and end break rate.
Figure 11.1 (e–f) Parameters influencing yarn tension during spinning
11.2.6 Winding on angle

Winding angle (Ø) influences yarn tension. The tangential pull exerted by the
yarn to lift the traveller and rotate around the ring is determined by ratio of
bobbin to ring radius/ diameter (Fig. 11.1 (g)). Ring radius (a) being constant,
for smaller bobbin diameter tangential component (Sin Ø) is smaller than
radial component (Cos Ø). Yarn has to work more to rotate the traveller,
increases yarn tension. Similarly yarn tension will be less for larger bobbin
diameter.
Since tapered bobbin is used in spinning, the tension level and the
difference in tension between the bottom and top of a cop changes with the
winding angle. This difference increases as the bobbin increases in the degree
of fullness. If the balloon height is too short, the value of the tension level rises
even at the beginning of winding (doff). Although balloon height is small, the
number of yarn breakages is about the same as at the beginning, of winding
due to triangular balloon formation and winding on the smallest diameter of
cop.
It is found that when winding angle becomes smaller than 23°, the radial
pull would be too high as to preclude the movement of the traveller. So, the
ratio of bobbin to ring diameter has to be suitably selected such that Ømin is
greater than 23°. Normally the minimum winding angle is kept at 25° to 30°,
to avoid higher end down at this point.
11.3 References
12
Means of controlling spinning tension variations
Abstract: The spinning tension in the yarn is desirable up to certain limit but
going beyond that results in excessive end breakage. Rather than average
tension value, the peak value of spinning tension is more important in this
regard. Because when the peak tension exceeds the yarn strength, especially
at weak point in the spun yarn, it leads to end break. Apart from that, working
under a very high spinning tension results in deterioration of yarn quality. So,
measure and control to spinning tension at an optimum level throughout the cop
build need to be applied.
Key words: End break, yarn cost, spindle drive, movable spindles, dual drive,
dual motor drive, inverter motor drive, ring data, variable speed drive
12.1 Introduction
The spinning tension in the yarn is desirable up to certain limit but going
beyond that results in excessive end breakage. Rather than average tension
value, the peak value of spinning tension is more important in this regard.
Because when the peak tension exceeds the yarn strength, especially at weak
point in the spun yarn, it leads to end break. Apart from that working under
a very high spinning tension results the deterioration of yarn quality. So,
measure and control to spinning tension at an optimum level throughout the
cop build need to be applied.
12.2 Means of controlling spinning tension variations

The spinning tension in the yarn is desirable up to certain limit to accomplish
the following objectives:
i. To ensure the formation of well packed yarn structure by causing the
fibers to be twisted in a straightened configuration.
ii. To ensure the formation of stable balloon envelops sufficiently large
to hold the package within it and
iii. To ensure the production of a firm package by providing necessary
tension during winding.
The end breakage rate rises steeply with increasing spinning tension
and its variation. In this respect, the peak value of spinning tension is more
important than the average value and for a better performance of ring frame;
the peak value of spinning tension should be lower. Because when the peak
tension exceeds the strength of weak places in the yarn, it leads to end break. In
addition, a very high spinning tension results the deterioration of yarn quality
parameters, such as elongation-at-break, unevenness and imperfections.
Hence is becomes necessary to measure and control spinning tension at an
optimum level throughout the cop build.
12.3 Yarn tension contributors

Continuous variation of the operating conditions arises during winding of a
cop. This variation is especially large with regard to changes mainly in terms
of balloon height and winding diameter (Fig. 12.1). Sequence of yarn tension
variation only due to balloon height change is as follows:
Figure 12.1 Factors causing yarn tension variations during spinning

Means of controlling spinning tension variations 181
i. Highest yarn tension occurs in the beginning of doff (Cop heel) due
to highest balloon height.
ii. Yarn tension goes on reducing with advancement due to reduction in
balloon height.
iii. Again higher yarn tension at the end of doff (Shoulder heel) due to
triangular balloon formation.
Similarly yarn tension is highest when wraps have to be formed on
the bare tube (small diameter), and lowest on the full cop circumferences
(large diameter). It has already been mentioned that tensile force (FT) must
be assumed tangential to the cop circumference because it arises from the
winding point. Frictional force (FR) undergoes only small variations; it can be
assumed to be the same in both cases. The components of tensile force (FT)
of the yarn tension are then also equal. However, owing to the difference in
the winding angle (Ø), the tensile forces FT = FW Sin Ø are different; less for
smaller angle (Ø) and higher for larger angle (Ø). The result is that the tensile
force exerted on the yarn is much higher during winding on the bare tube than
during winding on the full cop diameter because of the difference in the angle
of attack of the yarn on the traveller.
When the ring rail rises during layered winding, i.e. from a large to a small
winding diameter (slowly upward but faster downward pace), yarn tension
increases substantially, and ends down frequency increases accordingly.
According to a study carried out by Zinser, most thread breakages occur when
the ring rail rises in the upper (not the highest) zone. In order to maintain
thread tension and ends down at constant levels, spindle speeds should be
reduced when the ring rail is raised (control of layering speed).
However, the yarn tension at any instance of cop building is the net effect of
both the variables (balloon height and winding diameter). Thereby yarn tension
is substantially higher when the ring rail is at the upper end of its stroke, than
when the ring rail is at its lowest position, in spinning onto the tube.
Tension variations are not occurring only at the particular point of cop
winding (e.g. formation of the base); but arise at very short intervals in each
ring rail stroke. However, balloon tension is decisive between two. Thereby,
highest tension is recorded in the beginning of doff. This drops progressively
with the build-up of the bobbin diameter and reduction in balloon height.
Although at the end of doff, winding is carried out with smallest balloon, its
triangular shape increases yarn tension again. Additionally highest winding
tension is prevailing at the minimum diameter (tip) of the bobbin. Net effect
of both shows rise in yarn tension at the end of doffs but still less by 1.35 times
to the beginning of doff. This is mainly attributed to domination of balloon
tension over winding tension.
12.4 Means for controlling balloon height

Change in winding on diameter of bobbin is mandatory due to its shape and
bobbin build-up pattern adopted. Apart from this balloon height, the major
contributor towards the yarn tension, goes on varying throughout the cop
build up. So, it becomes necessary to spin yarn with controlled balloon height,
to avoid major tension fluctuations. Two concepts were put forward, viz.
(a) Use of movable spindle rail (conventional) and
(b) Use of movable lappet guides in synchronization with ring rail
(Modern).
12.4.1 Movable spindle rail concept

Movable spindle concept for constant balloon spinning was launched by Rieter
in the commercial market in late 40s. Spindle rail was made movable instead
of stationary as on modern ring frame. It was given downward descend for
the advancement (switching traverse). The major advancement was obtained
by the downward displacement of spindle rail along with partial descend of
lappet guide (Fig. 12.2 (a)). A very small descend (h) was given to lappet
guide in the beginning of doff to reduce balloon height B1 to B2 and thereby
yarn tension. This was done to avoid higher end breaks occurs at maximum
balloon height. Since ring rail position remained unaltered throughout, the
working balloon height and thereby yarn tension was pretend constant thence
after. Thus machine was put to higher spindle speed after the base formation
of the cop. Small advancement (approx. 10% of lift) was given toring rail
at the end of doff to offset rise in yarn tension while winding at the smallest
diameter.
However conceptionally, it found impressive but practically invites many
complications in builder motion drive. Power cost as well as wear and tear
involved was high due to movement of heavy spindle rail. Since positively
driven spindles are born by spindle rail, it became utmost difficult to control
tape and belt tension constant. This had lead towards higher between bobbin
count and twist variations. Due to all these limitations, although logically
sound strong, this concept has not found space in commercial production
process.
12.4.2 Concept of movable lappet guides and balloon

control rings in synchronization with ring rail
Movable spindle rail concept gets obsolete due to its practical limitations
and nowadays replaced by movable lappet guides and balloon control rings
in synchronization with ring rail concept on all ring frames. In this concept
during layering traverse and switching traverse, lappet guide and balloon
control ring also moves in synchronization with ring rail, as explained in
earlier section of builder mechanism. However, their magnitude of movement
is restricted by spinning geometry. Hence the system maintains balloon height
almost constant, yarn tension variations gets minimized (Fig. 12.2 (b)). Apart
from these lighter parts participates in the movement, so power consumption
is less. No complications arise in drive as ring rail do not bear any positively
driven element like spindle. So, system assures quality at an economical rate
as compared to earlier concept.
Figure 12.2 Spinning with constant balloon height
12.5 Means for controlling spindle speed

Although means are taken to control balloon height during cop build-up,
some inherent yarn tension variations are likely. They are mainly attributed to
continuously changing values of contributors (Fig. 12.1) and liable to cause
higher end down at peak points. Hence yarn tension varies in direct relation
to spindle speed, the higher end breaks frequency is controlled by adjusting
spindle speed accordingly. This control options should be provided at least a
start-up step (to prevent start-up thread breakages), a base step (for forming
the cop base) and a normal step (for winding the cop as a whole). Since tension
rises at the top most position (Fig. 12.3 (i)), there is often also a spin-out step
for winding the topmost part of the cop, which can be identical to the base
step.
Different options available on conventional to latest modern ring frame
to serve the purpose. Definitely they are differing in terms of working pattern,
accuracy and economy. They are as follows:
i. Dual speed drive
ii. Dual motor drive
iii. Variable speed drive
iv. Inverter motor drive or frequency-controlled drives
12.5.1 Dual speed drive

Conventional ring frames were provided with step pulleys for machine and
motor (Fig. 12.3 (ii)). The flat belt is shifted manually to slow speed [D1 to
D4] for high tension spinning zone; cop heel and shoulder heel. This has been
shifted back to the normal high speed [D2 to D3] for low tension zone; main
body build-up of the bobbin. However this exercise was done manually, so
always remain operator bias.
12.5.2 Dual motor drive

Modern ring frames are nowadays provided with either dual motor drive
or variable speed motor drive. In this set up, sensor transfers the signal
automatically to operate the machine at slow speed or fast speed. However,
the former is a cheaper option compared to the later one.
Two different motors are employed for getting dual speed with dual
motor drive (Fig. 12.3 (iii)). Slow speed motor (M1) is switched on for high
tension belt by the sensor and similarly high speed motor (M2) for low tension,
normal body build up. The changeover is accomplished by limit switches
automatically. This offers effective reduction in power cost. But following
draw backs get exposed:
i. The change over from the slow speed to fast speed is in one step,
sudden and therefore jerky. Higher end breaks are noticed during the
changeover.
ii. Higher mechanical stresses are imposed on revolving parts (traveller).
Sudden change in the speed adds to abrasion and adversely affecting
their life.
Figure 12.3 (i- iii) Methods used for controlling yarn tension during the doff
12.5.3 Variable speed drive

This system has been launched for overcoming the limitations of dual motor
system. The speed adjustment is done by means of adjustable grooved discs
(Fig. 12.3 (iv)) in the belt drive, similar to a cone transmission. Motor and
machine pulleys are not fixed diameter pulleys but in the form of two conical
plates. Distance between two plates is adjustable and effective diameter is
determined by the distance between two plates.
If the discs of one pulley are moved apart and those of the other pulley are
moved together, the drive belt passes onto a larger diameter of the one pulley,
and a smaller diameter of the other. The change is operated automatically via
sensor, it identify cop build up position and operates pneumatic or hydraulic
piston (e.g. LMW G 5/1 Ring frame). This in order expands or contracts
driving pulley via lever mechanism for increasing or decreasing machine

speed at the respective tension belts.
Figure 12.3 (iv- v) Methods used for controlling yarn tension during the doff
The piston movement is governed through specially designed

microprocessor software which activates solenoid valves. They in turn control
the movement of the piston and thereby driving pulley shaft speed. There
is virtually no limitation on number of steps to be chosen for increasing or
decreasing spindle speed.
Gradual acceleration and retardation helps in optimizing spindle speed for

different doff positions. This offers higher productivity, effective reduction in
power cost along with elimination of additional motor cost.
12.5.4 Inverter motor drive

All above concepts takes care of only three main tension zones of bobbin
build up and ignores effect of traversing on yarn tension. Apart from this
motor speed remains constant and only machine speed gets changed as per
need. Inverter drive system differs from all these (Fig. 12.3 (v)). Here motor
speed itself is changed, as per need, by changing the frequency of electric
supply. Thereby it is also referred as frequency convertor motor drive.
The new concept of inverter control drive or frequency convertor drive
has been adopted on latest high speed ring frame (Rieter G35). The basic rule
for motor speed is:
12 × F
Motor speed = [Eq. 12.2]
P
Where, 120 is a constant, F is frequency of electric supply and P is
number of poles of motor. Thus motor speed is directly proportional to the
frequency of electric supply and by changing the frequency; motor speed
can be proportionately altered. Normal frequency of electric supply is 50 Hz.
Inverter changes this frequency from 28 Hz to 60 Hz in one of the commercial
model available. For achieving this AC is first converted into DC, then it is
subjected to Pulse Width Modulator (PWM) and then it is converted back
to AC before it is supplied to the motor. Characteristics of AC before and
after inverter are different. The frequency changes are effected through
microprocessor software and even finer adjustments are possible.
End breaks on ring frame are highly variable and mainly affected by
the doff position, machine speed and condition, quality of feed material
and atmospheric conditions. Thereby continuous manual monitoring and
control is neither feasible nor economically viable. Microprocessor software
continuously senses yarn tension during cop build up, for each and every coil
laid and accordingly varies spindle speed via inverter control automatically.
This controls energy input as a function of rotation speed. Energy consumption
of the drive motors can thus be optimized. Provides the best possible control
on yarn tension and facilitates higher production rate with zero possibility of
end break.
The system can also incorporated with online monitoring system: ‘Ring
Data system’. It continuously assesses ring frame wise end breakage rate and
link with microprocessor software to control spindle speed accordingly. Speed
is kept higher for low end breakage rate and low for higher rate. Going one step
ahead, this microprocessor software for inverter control drive is alliance with
Programmable Logical Control [PLC] Unit in addition to Ring Data. Group
of ring frames equipped with software and ring data system can be controlled
through a PLC unit from a remote place also. Thus system promises unlimited
scope to alter the machine speed as per requirement. There is no mechanical
linkages used, makes system sturdy and robust. There are no mechanical
losses.
The major shortcomings are:
• It demands higher initial investment as well as sophisticated
maintenance.
• Higher power consumption because of AC to DC and DC to AC
conversions.
• Higher temperature rise at the inverter demands installment of
efficient cooling system.
• Sudden impact caused with increase or decrease in traveller speed
along with spindle speed liable to reduce traveller life.
• Apart from these drawbacks this system is unbeaten till date.
12.6 References
1. Booth, J.E. (1975). Textile Mathematics (Vol. II), The Textile Institute, Manchester,
p.333.
4. Mahajan S.D. (March 2000). ‘Drives on modern ring frames’, NCUTE-PILOT
Programme on Ring Spinning, Doubling and Twisting, pp. 23–25.
6. https://nptel.ac.in/courses/116102038/24, Yarn Tension in Ring Spinning - nptel
7. https://www.schlafhorst.oerlikontextile.com/.../Ring/2014_06_Zinser_Roving_
Frame, [Accessed on 20 August 2014]
13
Optimization of ring spinning parameters
Abstract: Spinning parameters like ring diameter, lift of the package, traveller
mass and spindle speed have a greater influence on the quality and cost of ring
frame and thereby the entire ring spinning. It becomes necessary to optimize
these ring-spinning process parameters in order to curtail cost and increase the
production rate without affecting the yarn quality.
Key words: Productivity, ring diameter, spindle gauge, capital cost, labour
cost, doffing, limiting speed of front roller, traveller limiting speed, surface
characteristics, piecing efficiency, traveller mass, balloon size, production rate,
package power, yarn content
13.1 Introduction
Spinning parameters affecting productivity of the ring frame and thereby
the entire ring spinning. It becomes necessary to optimize the ring-spinning
process parameters in order to curtail cost and increase the production rate
without affecting the yarn quality.
13.2 Optimization of ring spinning parameters

The major variables influencing production rate and product cost and quality
at ring frame are;
• Ring diameter (R)
• Lift of the package (L)
• Spindle speed (n)
• Traveller mass (M)
13.2.1 Ring diameter (R)

Ring is one of the main element of ring spinning. It plays a major role in
spinning or twisting the drafted strand emerging out of front roller nip. Its
diameter has a greater influence on the economy and the quality of the ring
spinning product.
13.2.1.1 Effect on economy

Economy of the product depends on production rate and cost of production.
So, contribution of ring with respect to economy is evaluated in terms of these
two criteria.
(a) Effect on production rate

Spindle speed decides the production rate and thereby cost/Kg of the ring
frame. Higher the spindle speed higher will be the production and vice versa.
The spindle speed is restricted by the limiting speed of the traveller, which
in turn is affected by ring–traveller combination (in terms of their design,
surface characteristics) and diameter of ring itself. Effect of ring-traveller
combination is illustrated with an example.
Example: Conventional T-shape ring and C-shape traveller system of
ring frames are operating with lower limiting speed of traveller; 70 ft/s (21
m/s). Let’s assume ring diameter is 2 inch. So, maximum attainable spindle
speed (nmax) can be
12
Traveller speed (ft/s) × = π × DR in inches × ns in RPM [Eq. 13.1]
60
70 × 60 ×12 inches/min
nmax =
π × 2 inches
= 8021 rpm (\ 1ft = 12 inches)
Modern orbit ring-traveller system operates with higher limiting speed of
the traveller: 134 ft/s (40 m/sec). For the identical ring diameter of 2 inch, the
maximum attainable spindle speed is:
134 × 60 ×12 inches/min
nmax =
π × 2 inches
Thus with orbit ring-traveller due to reduced ring–traveller friction and
better heat dissipation during spinning higher spindle speed can be attained.
This is mainly attributed to improved design and surface characteristics of the
ring-traveller combination. Ring diameter is kept same, viz. 2 inch in both the
cases. However, modern ring frames are operating with smaller diameter ring
irrespective of yarn count. It becomes interesting to identify the influence of
change in ring diameter on ring frame economy at this point.
Effect of ring diameter is again explained with an example.
Example: Let’s assume two different ring diameters 38 mm and 50 mm
for modern orbit ring- traveller system operates with higher limiting speed of
the traveller: 134 ft/s (40 m/s).
Then maximum attainable spindle speed (nmax.) for 38 mm ring will be
Optimization of ring spinning parameters 191
134 × 60 ×12 × 25.4 mm/min

nmax = = 20,471 rpm
π × 38 mm
And with 50 mm diameter ring:
134 × 60 ×12 × 25.4 mm/min
nmax = = 15,354 rpm
π × 50 mm
Thus higher spindle speed and thereby production rate can be achieved
with the use of smaller diameter ring for the identical combination of ring-
traveller (Fig. 13.1).
Figure 13.1 Effect of ring diameter on maximum spindle speed
(b) Effect on yarn cost

The major share to yarn cost is coming from the raw material cost. Hence ring
diameter has no contribution to raw material cost but it affects cost influencing
parameters other than that. They are power cost, labour cost and capital cost.
(i) Effect on power cost: Cop is mounted on the spindle, which is driven
positively on the ring frame. Thus efforts have been put up to drive spindle
weight and package weight. Hence spindle weight is constant for the given set
up; the magnitude of efforts goes on changing with respect to package weight.
Power required to rotate the package is referred as package power (P). Bigger
and heavier package gets build up with bigger diameter ring, according to the
relationship,
Full package diameter = Ring diameter – 3 mm [Eq. 13.2]
The package power (P) also changes relatively. The experimentally
derived relationship between them is as follows:
P ∞ D2.75 [Eq. 13.3]
Thus power consumed increase 2.75 to the power of ring diameter. This
hike the yarn cost considerably.
(ii) Effect on labour cost: Full bobbin diameter is restricted by the ring
diameter (D). It is always kept 3 mm lesser than ring diameter for ease of
traveller rotation as mentioned above. Smaller the ring diameter, then
smaller the allowable full bobbin diameter and there by its yarn content.
Approximately,
Package Capacity ∞ Ring Diameter2 [Eq. 13.4]
Modern ring frames operates with smaller diameter ring. So, allowable
yarn content of the package is less. Higher delivery speed of the machine, the
package builds up fast and increases doffing frequency. Manual doffing is the
time consuming exercise, increased down time of machine for higher doffing
cycles adversely affects machine efficiency. Thus modern ring frame are
equipped with auto doffing, to shorten doffing time considerably few seconds
instead of 30–40 minutes. But it demands additional initial investment and
maintenance cost. However, increased machine efficiency with its higher
production rate can pay back it in a short time. Similarly, use of larger diameter
ring on conventional ring frame without auto doffing can be well justified.
(iii) Effect on capital cost: Spindle gauge, ‘center to center distance of
two consecutive spindles on ring frame’ is dependent on the measure of ring
diameter. As explained in spinning geometry, permissible balloon diameter
is based on ring diameter apart from other factors. So, minimum viable
allowance needs to be kept between two neighbouring spindles. Thus bigger
the ring diameter higher is the spindle gauge value. This permit less number
of spindles to be get accommodated on the given length of machine. Reduced
number of working heads per machine demands more number of machines
to be installed to meet the desired production rate. The initial investment for
procuring higher number of machines, space occupied, labour employed,
power consumed, maintenance, etc. associated with production course are
accordingly higher.
Summarizing the entire discussion the yarn cost involved is higher while
spinning with large diameter ring than smaller one. However, use of auto
doffing system is mandatory for ring frames with smaller diameter rings.
13.2.1.2 Effect on yarn quality

Ring spinning is the final stages of yarn formation. Any defect in processing
at this final stage may lead to the formation of defective yarns and also higher
end breakage. End break also introduces yarn faults due to splicing or piecing
apart from production loss and loss of good fibers in waste (Bonda waste). It
is therefore extremely important to keep the spinning process under control
to deliver yarns with the desired quality at the highest possible speed but
with minimum waste. Spinning tension and end breakage rate are the key
parameters which need to be under control for acquiring yarn of desired
quality. Uniformity and strength are the two major parameters used for
evaluating yarn quality.
Selection of ring is mainly restricted by spinning tension. The basic
condition for stable spinning demands that spinning tension should not exceed
yarn strength, otherwise results in excessive end breaks. While spinning with a
constant balloon height (H) and spindle speed (ω or n), on a given ring frame,
yarn tension varies with yarn count. This change is mainly attributed to centripetal
force (C = MRω2) required to rotate lighter or heavier mass of the yarn. So, for
obtaining a constant yarn tension either the traveller weight (M) or the spinning
ring diameter (2R) has to be changed. Hence traveller mass is selected according
to yarn linear density as mentioned in previous section, relationship of yarn
tension with ring diameter need to be elaborated at this vary point.
This can be explained with an example. Let’s assume that yarn tension
is compensated by diminishing only the ring diameter (D) for a given count
under the identical conditions of spinning. It will result in packages of
disproportionally small diameter, with low yarn content, adversely affects
economy as mentioned above. Even reaching the value taken for the ration
d/D becomes impossible under mill condition. Where’d’ is the measure of
bare bobbin diameter. This exceeds yarn tension at the end of doff due to too
low winding on angle, results in excessive end down. This adversely affects
yarn quality as well cost. However, within the ranges of particular yarn counts
changing the ring are to be avoided for controlling yarn tension. Since it is
not a practically viable option. Normally package density is controlled by
changing the traveller weight only.
Concluding the entire discussion as follows:
The selection of ring diameter is thus restricted by yarn tension and the
minimum angle of lead, as well as other factors such as power consumption,
spindle rpm, and traveller speed limitations. Although a large diameter ring
increases yarn tension as well as cost, it is thought desirable, for spinning
heavier thicker counts. The yarn is strong enough to withstand the increased
tension and a larger package can be build up without facing excessive end
breaks. Higher yarn content of cop reduces doffing frequency and thereby
unproductive downtime of ring frame. These frames with less number of
spindles are normally provided with manual doffing option for imparting
economy.
On the contrary, smaller rings are employed while spinning finer counts
along with auto doffing system. This helps in attaining desired centripetal
forces with the traveller mass, chosen according to the linear density of the
yarn being spun. Thus ensures spinning of good quality and economy of
costlier yarn. Higher investment for auto doffing is offset by reduced labour
cost and number of machines.
In practice selection of ring diameter depends on
• Quality of raw material and yarn
• Yarn count
• Production rate / spindle speed
• Availability of labour, their cost and type
13.2.2 Lift of the package

Lift of the package refers to the available height of the bobbin for yarn
winding. It is a next important variable to ring diameter, influencing economy
and quality of ring spun yarn.

Labour cost and power cost are the two main cost contributors that get affected
directly by the change in package lift value. So, analysis of this measure with
respect to ring spinning economy need to be done in these regards only.
Contribution of labour cost: Production of any ring frame for its set
delivery speed gets change in direct relation to machine efficiency. Hence
spinning efficiency is closely related to number of doffs per shift. With the
increase in package lift (L), yarn accommodated on it gets increased. It
widens doffing interval and reduces number of doffs per shift. Positively
contribute to machine efficiency and thereby increases its production rate.
Higher production per unit time along with reduced labour hours involved
makes the product (cost/Kg) economical. So, it is labour cost point of view
more viable to spin with longer lift package.
Contribution of power cost: The major share of power cost is born by

the package power. It varies in direct proportion to package weight, purely
influenced by its dimensions. This necessitates the optimum shaping of
spinning bobbins in terms of its diameter and lift. Hence diameter of the full
bobbin is limited by ring diameter and lift by its height. Package power gets
increased with package lift (height). However, package power (P) required
for bobbin build by varying lift (L) or ring diameter (DR) is different. Their
relationship is given below:
P ∞ L [Eq. 13.5]
for given constant ‘DR’ and
P ∞ DR2 [Eq. 13.6]
for given constant ‘L’.
Hence package power is mainly attributed to the weight (W) of such a
buildup package. The relationship between these two is also equally important
at this end. They are as follows:
P ∞ W1.375 [Eq. 13.7]
for the package build up, with larger ring and by keeping the lift constant.
Whereas,
P ∞ W [Eq.13.8]
for the package build up,with higher lift bobbin and by keeping the ring
diameter constant.
Thus it is more beneficial to increase yarn content of the package by
increasing package lift (L) rather than ring diameter (DR) in terms of power cost.
Summarizing entire discussion, it can be concluded that spinning will be
more economical with longer lift package.
13.2.2.2 Effect on yarn quality

Package lift defines maximum balloon height (H) formed at the point of
base build up. Higher the lift of the package more will be the balloon height.
Since yarn tension varies in direct proportion to balloon height, end breakage
rate increases with increased lift. This adversely affects yarn quality due to
increased piecing faults. Yarn cost also increases due to increased down time
for piecing and Bonda waste. End breakage rate can be reduced for bigger lift
package either by operating at slow spindle speed (n) or introducing balloon
control rings. The former one reduces production rate and thus increases
yarn cost per kg. The latter one increases abrasion between yarn and balloon
control ring, invites hairiness and fly generation. Both the conditions are
unacceptable in terms of yarn quality and standard of housekeeping to meet
statutory requirements.
Selection of package lift is purely based on balloon theory. Accordingly

package lift should be such that the balloon height (H) must be less than πP,
where πP represents the length of node. Otherwise balloon interfere enveloped
rotating bobbin and gets collapse and spinning becomes impossible. Thus, use
of balloon control ring is mandatory for longer lift package apart from its
associated disadvantages in terms of yarn quality if spinning to be continued.
Even longer lift packages offers larger diameter variations from tip to
base. This leads to more deviation in traveller speed owing to difference in
winding revolutions. The significant change in traveller speed at the smallest
package diameter and largest one brings about within bobbin twist and thereby
count variations. Thus use of longer lift package adversely affects product
yarn quality.
Conversely smaller lift packages prevents balloon collapse, use of balloon
control ring, occurrence of higher end down and twist variations. Thus assures
the precision of yarn quality delivered.
Summarizing the entire discussion as follows:

It is viable to use smaller lift package for quality conscious finer yarn spinning.
The higher yarn cost due to increased doffing frequency can be offset by the
use of auto doffing. Spinning of coarser yarn is economized with the use of
longer lift package along with use of balloon control ring. Focus is more on
economy rather than quality in this case. Thereby attention is paid to faster
bobbin build up even by sacrificing some quality (hairiness) for coarser yarn.
13.2.3 Spindle speed (n)

It is the fastest driven part of the ring spinning. Its speed defines twist value
and also controls directly delivery speed of the machine as per the set twist
value. Thus it has a greater influence on yarn quantity as well as quality

Spindle speed is always kept optimum and front roller speed varies according to
twist level. Higher spindle speed is possible for low twist and vice versa. Thus
for the identical twist value if spindle speed can increase, proportionately rises
front roller delivery speed. Higher the delivery speed, higher the production
rate and yarn cost per kg gets reduced. This also permits to work with less
number of machines for meeting the targeted production. This reduces capital
investment due to saving in space, labour, power, maintenance, etc. involved
in the course of production. All together makes yarn more economical. So,
working with higher spindle speed is economy point of view preferable.
Looking at the other side of the coin, practically attainable spindle speed
is always lower than the one claimed by the manufacturer. Limiting speed of
the traveller (TL), surface speed of front roller and end breakage rate are the
major controller in this regards.
Influence of limiting speed of the traveller (TL): Thermal damage cause
to traveller at higher friction between ring-traveller is referred as traveller
blueing or burning. The friction between ring-traveller increases with spindle
speed. So, it becomes necessary to run spindle (thereby traveller) below the
speed causing traveller burning. This speed is known as limiting speed of
traveller. Thus spindle speed gets restricted by traveller limiting speed. Its
value differs as per type of ring-traveller, their surface characteristics (type of
material) and amount of twist. That’s why ORBIT ring-traveller can permit
high spindle speeds in comparison to T-ring and C-shape traveller combination
(Table 13.1).
Table 13.1 Influence of Ring-Traveller Type on Spindle Speed
Øring (mm) TL (m/sec) Nmax. Ring –Traveller type
50 mm 21 8, 025 T-ring and C-shape traveller
50 mm 42 16, 050 ORBIT ring –traveller
This is mainly attributed to higher area of contact between ring and

traveller which permits faster heat dissipation along with less heat generation
due to use of improved metallurgy (reduced coefficient of friction). Both
together delays thermal damage and permits higher spindle speed.
While spinning pure cotton, fiber-lubricating film can reduce the friction
and enhance the limiting speed value. But spinning of pure manmade or
blends not able to generate same amount of lubricating film. This can alter the
limiting value of traveller speed although it is kept identical.
Influence of surface speed of front roller: Whenever end breaks piecing is
done. Quality of piecing and piecing efficiency become poor with higher front
roller speed. Here piecing efficiency refers percentage of successful attempts
with respect to total number of attempts made:
Number of successful attempts
% Piecing Efficiency = × 100 [Eq. 13.8]
Total number of attempts
Piecing efficiency becomes further poor, if it is done at nip, viz. vertical
drafting system than done at side, viz. inclined drafting system. Thereby front
roller speed gets limited by 12 m/min in the former case as compared to 18
m/min attained in the latter case. The value for inclined drafting system can
be enhanced further by imparting proper training and giving incentives to the
workers up to 25 m/min.
Effect of limiting front roller speed on the allowable spindle speed can be
explained by example.
Example: Let’s assume two yarns, one is coarser (9 Ne) and another
finer (64 Ne) spun with identical twist (T.M. = 4) on the modern ring frame
provided with orbit ring–traveller system and inclined drafting. The limiting
speed of front roller for the given machine set up is 25 m/ min.
Spindle speed (rpm)
TPM = [Eq. 13.10]
S.S. of front roller (m/min)
Where,
TPM = T.M. × Ne × 39.34 [Eq. 13.11]

\ Maximum spindle speed nmax = PM × surface speed of front rollermax.
in (m/(m/min)
Thus maximum attainable spindle speed for coarser count (4s Ne) is
12,000 rpm. It is much lower than permissible spindle speed owing to traveller
limiting speed (16,000 rpm) for the given machine set up. Thus for coarser
count, although possible, limitations of front roller surface speed imposes
restriction to higher spindle speed.
For the finer count (64s Ne), maximum attainable speed with respect to
front roller speed is 32,000 rpm. It is much higher than the permissible one in
terms of traveller limiting speed. Although possible higher spindle speeds are
here restricted by the traveller limiting speed for finer count spinning.
Contribution of end breakage rate: When yarn tension exceeds yarn
strength during spinning, results in end break. Yarn tension (Tgm) is directly
proportional to the square of the traveller or spindle speed (n).
T ∞ n2 [Eq. 13.12]
Thereby higher spindle speed is used for stronger warp as compared to
weaker weft yarn spinning. Similarly knitted yarns hold less amount of twist
weaker in nature. Thereby not able to sustain higher stresses at increased
spindle speed. Such yarns spindle speed is not restricted by traveller limiting
speed but by yarn strength itself. On the contrary for the stronger manmade
fibers or their blends, strength is not a problem even at low twist level. But their
friction work between ring and travellers brings about the earlier limitations
in spindle speed.
Major contributor to yarn tension during spinning is balloon height (H in

cm). According to balloon theory the maximum allowable spindle speed for a
given yarn size (N in tex), without causing break is:
94.6 T
\ nmax <   [Eq. 13.13]
π N
Accordingly maximum attainable spindle speed is less for finer yarn (low
value of N) and more for coarser yarn with the virtue of an end break.
13.2.3.2 Effect on quality

As mentioned above yarn tension varies in square proportion to the spindle
speed. Thereby working at higher speed, spinning tension is high, improves
fiber orientation and makes it stronger. This reduces chances of end down,
conditional the yarn stress value is less than its strength.
Summarizing the entire discussion:

It is beneficial to work with higher spindle speed as it enhance production rate
of the machine irrespective of yarn count. But working at higher spindle speed
should not be at the cost of yarn quality or with higher end breakage rate.
Although permissible higher spindle speeds are not attained practically by
finer yarns due to traveller limiting speed and for coarser yarn due to limiting
front roller speed.
13.2.4 Traveller mass (M)

The minimum traveller mass for a particular ring frame should be just
sufficient enough to prevent balloon collapse during winding on the shoulder
of the cop bottom, that is, during winding at the maximum balloon height onto
the maximum package diameter. Since both, the minimum balloon tension
and the traveller-ring frictional force are approximately proportional to the
square of the spindle speed. The mass of the lightest traveller that can be used
is thus largely dependent of the spindle speed (n).
An approximate value of the minimum traveller weight, M, in grams is
given by the expression
0.000048H 2 N
M = [Eq. 13.14]
2R
Where 2R and H are in inches and N is in tex. Thus minimum traveller
mass is:
• Inversely proportional to the ring diameter, 2R,

• Proportional to the count, N (in tex), and
• Proportional to the square of the balloon height, H

Heavier traveller itself is costly. Rotating such a heavy body efforts required
are more, so power consumption is more. Increases yarn cost.
Traveller mass controls winding tension. Use of heavier traveller results
in a compact package with increased capacity. This reduces downtime of
machine and enhances machine efficiency by reducing doffing cycles. This
makes yarn economical.
Traveller mass is one of the decisive factor for generating higher
centripetal force required for heavier coarser yarns for constant ring diameter.
Thus spinning without causing traveller fly or end break becomes possible
without changing basic machine set up (ring diameter) for different yarn size
to be spun, only by changing traveller mass. Hence traveller change is speedy
and more economical, this positively contributes to yarn cost.
13.2.4.2 Effect on quality

Traveller acts as a mediator between spinning and winding zone. So, change
in traveller mass affects both the zones performance equally.
Higher spinning tension, increases yarn strength by parallelizing the
fibers as they are emerging out of the delivery roller nip, and thus reduces the
end-breakage rate. This permits higher spindle speed with the use of heavier
traveller.
Balloon diameter reduces with the use of heavier traveller. This reduces
chances of lashing with neighbouring balloon and thereby occurrence of
undesirable multiple end breaks. This can allow spinning to be continued at
higher efficiency without using separators. Elimination of separators reduces
yarn damage (hairiness) caused due to rubbing.
Summarizing the entire discussion:

The traveller mass is usually chosen according to the linear density of the
yarn being spun. The maximum traveller mass permitting a good spinning
condition (strength and balloon dimension) is chosen, to give an acceptable
end breakage rate. Where the choice is lying between lighter and heavier
traveller, latte one is preferred for quality as well as quantity point of view.
13.3 References
1. Azarschab, M. and Renner, G. (1995). ‘Influence of high speed
spinning on the properties and downstream processing of yarns’,
Melliand Textileberichte, p. 964.
2. Carl A. Lawrence (2003). ‘Fundamentals of Spun Yarn Technology’,
CRC Publications.
3. Datta, B., Kanjilal, S.K., Bagga Anil, and Mehta, N.C. (1983).
‘Optimum package size in ring spinning frame-I’, The Indian Textile
Journal, p.73.
4. De Barr and Catling H. (1965). ‘Manual of Cotton Spinning: The
Principles and Theory of Ring Spinning,’ Manchester, The Textile
Institute.
5. Eric Oxtoby (1987). ‘Spun Yarn Technology’, Butterworths & Co.
Ltd., London.
6. Hasanuzzamana, Pranab K. Dana and Sanghita Basu (2014).
‘Optimization of ring-spinning process parameters using response
surface methodology’, Journal of Textile Institute, Taylor & Francis
Online, Accessed on 25 August 2014]
7. Klein W. (1987). ‘The Manual of Textile Technology: Vol. I – The
Technology of Short Staple Spinning’, Manchester, The Textile
Institute.
8. Lord P.R. (2003). ‘Hand Book of Yarn Production: Science,
Technology and Economics’, Taylor and Francis.
14
Material handling
Abstract: Labour involved in material handling at conventional ring frame accounts

for almost 50 percent or more of total labour employed in this department. It is
an obvious candidate for the faulty production, production delay, higher storage
and definitely added cost. It becomes obvious that material handling can be
made automatic on longer length high-tech ring frames. However, it is done with
higher initial investments.
Key words: Material handling, labour, inter-linking of machines, inter-connected
transport, economy, faulty product, power consumption
14.1 Introduction
Labour Employment Ratio (LER) is one of the major indices in defining and
controlling productivity of spinning units. As labour is another major contributor
to yarn cost apart from raw material and power cost. Raw material cost can be
optimized by using scientific methods of mix formulation techniques, which
are beyond the scope of this book. Various measures are taken for optimizing
power consumption of ring frame. Spindle drive is the major power absorber
of the entire ring spinning system. The measures taken for optimizing power
consumption at this end have already been discussed in Chapter 12. Thus left
behind variable is the labour compliment. Almost 50–60 percent of total skilled
and unskilled labours are employed in ring frame section only for classical
mode. They involved in various activities like, machine operation, maintenance,
cleaning and material handling. Out of total unskilled labours almost 50–60
percent is involved in the material handling activities. Manual material handling
is an obvious candidate for the faulty production, production delay and higher
storage, also adds to labour cost. It becomes obvious that material handling can
be made automatic on longer length high production ring frames. However, it is
done with higher initial investments.
14.2 Conventional mode

Conventional ring spinning had larger proportion of unskilled labour
involved in material handling at ring frame section. They were doing jobs
Material handling 203
of creeling, doffing, transporting full cops from ring frame to winder and
roving bobbins from speed frames to ring frames, handling Bonda waste.
Whereas skilled labours like tenters, jobbers, etc., were dealing with process
control and machine maintenance exercises like, count change over, settings,
conducting rounds for idle spindles, snap study, piecing, initiating doffing
and restarting with new doff, etc. Industries were normally seeking for the
trained personnel for these jobs by paying higher wages. But the unskilled
labours involved in material handling mainly, were not able to earn higher
wages. However, keys for the quality of end product were lying in the hands
of such labours only, even though having a less share in ring frame labour
cost.
Faulty manual material handling practices were liable to create havoc.
As an example cross mixing of material (roving) of parallel counts running
in mill, leads to higher un-assorted product waste and badly impacting yarn
realization of the mill. This is mainly attributed to human fatigue comes out
of monotonous or ergonomically unsuitable working environment.
14.3 The need for automation

Automation replaces human activity with processes performed by machines,
apparatus or electronics. In terms of cost accounting this increases capital
costs for some reduction in labour costs. Automation is therefore worthwhile
in material handling, where lots of manual work has to be done in a poor
working environment.
Brief outlook at the yarn manufacturing processes used in the textile
industry, ring spinning involves a mixture of quality control and production
line operations. With the material testing as the predominant feature, quite a
large units of between the different stages. Material therefore hardly flows
along the shortest path in regular cycles from a production unit directly to the
same downstream operation every time. This type of manufacturing process
has four serious drawbacks:
i. Too high transport cost (almost 50–60 percent of total labour cost)
ii. Long material lead times (with correspondingly long delivery lead
time)
iii. Large volume intermediate storage of material to prevent back stuff
shortage. This makes substantial amounts of capital unnecessarily
tied up.
iv. Deterioration in yarn quality (e.g. cross-mixing) and damage to the
material (e.g. Slough off, stains etc.).
14.4 Automatic material handling

Modern ring frames have almost double the number of production units (1600–
1800 spindles) than the conventional ring frames (440–880 spindles). Apart
from that as mentioned in earlier sections ring frame bobbin size has reduced
considerable. All together has increased stress of material handling at feed
end as well as delivery end. So, there is a steadily increasing awareness of the
importance of transport in spinning mills and among machinery manufacturers
and that opportunities for improvement are being sought. Several textile
machinery manufacturers are already offering automated transport systems.
A distinction has to be made between two types of automated transport
equipment between ring spinning machines and winders:
(a) Interconnected transport and
(b) Interconnected machines
14.4.1 Interconnected transport

Interconnected transport as the name suggests deals with an automated
transport system (conveyor line) between two subsequent machines. It is
installed between the ring spinning installation and the winders. The transport
system accepts the cop crates, coded according to their contents at the ring-
spinning machine and conveys them to a distribution station. This station
directs the crates by microprocessor control to their correct destination, a cop
preparation unit on the relevant winder. The resulting empty tubes are laid in
other crates and return to the ring spinning installation via a second conveyor
system.
Interconnected transport systems offer following advantages:
• Very flexible
• Permit operations with small batches
• Quickly can be adapted
• Less dependent on the building
However, they can be rather complicated, liable to malfunction and
obstructive due to the conveyor lines.
14.4.2 Interconnected machineries

Modern long high-speed machines demand more efficient and accurate
systems for material handling. They are provided with material transport by
connecting two machines in sequence, e.g. ring spinning machine and winder
to form a production unit. This system facilitates slow and controlled pass
Material handling 205
to the cops, at the production speed of the winder units, in a direct line to
the downstream winder after doffing. Emptied tubes return to the doffer‘s
loading station on the ring spinning machine. The number of winder units
has to be chosen to ensure that the winding of doff is completed exactly when
the next approaches. The exact coordination between the two machines is
necessary otherwise it can be a great drawback of the system. If there are
frequent yarn count changes, then reserve winding capacity often remains
unused needs to be installed to provide for every eventuality. This results in
higher capital service costs. These systems are therefore ideal when operating
as far as possible with only one yarn count.
14.5 References
1. http://www.rieter.com [Accessed on 24 October 2014]
2. http://www. rikipedia.com [Accessed on 24 October 2014]
15
Measures of process control
Abstract: Process control program at ring frame has an utmost importance as it

addresses to final product. Conventional technique was slow, tedious and human
bias, thereby not permitting to meet better yarn quality at higher efficiency.
Sensor-based control system of latest high tech ring frames have overcome all
such limitations and guaranteed quality at higher productivity.
Key words: Machinery audit, snap study, efficiency, quality, labour, sensor,
spider web, ring data, ISM, online monitoring
15.1 Introduction
Process control in terms of machine parts condition, precise setting of process
variables and meeting specifications of product quality parameters is the
inherent feature for the success of any production house. Conventional ring
spinning system depends on the human expertise for the purpose being, thereby
lagging in terms of quality and quantity of production gained. However,
sensor-based online monitoring and control system of modern high-speed ring
frames have made this labour intensive exercise simple and precise.
15.2 Conventional approach

Conventional ring frames are operating with manual measures and controls.
Track for the proper working condition of machine variables is kept either
by visual judgment of the expert or by using mechanical tools like roller
eccentricity tester, roller hardness tester, etc. Even recording of measurement
was human bias. Process variables demands crucial manual calculation
based gear settings for draft, twist and package density. As mentioned in
previous sections also, they are badly suffering from the rounding off errors
and were not allowing in exactifying the customer’s demands at producer’s
end. Classical mode of spindle, drafting roller and builder mechanism drive
were further adding to within and between bobbin count and twist variations
due to inherent inbuilt high slippage of the system. Person needs to take
time in identifying point and cause for variation and production loss. Time
Measures of process control 207
consuming snap study for controlling end breaks and section wise and spindle
wise rounds for identifying causes for non- productive spindleage were taken
by skilled operators. These visual inspection was followed by brain storming
long statistical evaluation of data, before initiating corrective measures for
improving machine efficiency and thereby productivity. Even manual piecing
was done at the event of en down. Thereby not only piecing efficiency gained
was low but also human bias variations in the quality of piecing. Product
verification was off line and passing through time consuming, tedious non
automatic testing procedures. Even these practices demand lot of material
handling between production house and quality control center. Non-automatic
mode of testing was adding to skilled labour factor involved in ring frame
section. Slow testing speed followed by manually done statistical evaluation
before deriving conclusion were delaying the corrective measures taken for
preventing faulty production.
The conventional system thereby suffering from following major draw
backs:
(i) Higher LER at ring frame section due to human-based measures and
control
(ii) Human bias and delays in corrective measures
(iii) Absence of system for identifying cause of problem demands time
consuming and human bias exercises like snap study and spindle
rounds
(iv) Low machine efficiency and production rate due to higher percent
end breaks and percent idle spindle in the house
(v) Higher waste levels due to low piecing efficiency
15.3 Modern approach

Modern approach of process control at ring frame operates with the concept,
‘fault should be prevented rather than corrected’. This is very true for high-
tech spinning plant. It cannot be operated without management information
systems based on online quality assurance and productivity control. Otherwise
rejection will be huge with high performance machine, if anything goes wrong.
Immediate identification of cause and corrective measures are required. Sensors
are installed on the machines for quality assurance purposes, it sense and initiate
corrective measure automatically. There is no bifurcation in terms of machine,
process and product control, all is going together. A data collecting and data
evaluation system (SQC) is most important tool for such quality management
on electronically controlled ring frames. The system is manufactured under
different names by different machine manufacturers, like Rieter has developed,
‘Spider Web’ and ‘POLYLINK’ by Zellweger, etc. Few examples are mentioned
below to highlight working mode of such systems and the precision and ease of
control imparted by them in comparison with classical tedious exercises.
Ring data system consists of a traveling sensor, known as traveler, runs
continuously back and forth at the height of the ring rail on each side of the
machine on a single machine (pilot unit) or on all machines in the mill. This
generates a magnetic field that is affected by the rapidly rotating traveler. If
a yarn break occurs, the traveler ceases to rotate and the sensor displays the
resulting impulse as an end down, also recording the number of the spindle. As
a result of its rapid motion back and forth it registers the spindle several times
until the end down is repaired. Thus precise recording of spindle downtime
becomes possible. Another sensor fitted on the front roller records the delivery
speed and machine stoppages, thus gives exact record of production rate and
loss of fibers in Bonda waste as per the count running on ring frame. One
more sensor keeps the track for the number of doffs and their duration. All the
information collected is ultimately transmitted to a computer with monitor and
printer, which performs the necessary analysis and stores the data for preset
periods. The following data are available via reports on individual machines,
individual blends or the installation as a whole that are printed out or can be
called up on the monitor any time:
• Machine number
• Date
• Time
• Period monitored
• Production period
• Spindle speeds
• Yarn twist
• Output in kg
• Output in g/spindle /hr.
• Efficiency
• Downtimes
• Doffing times
• Number of cops doffed
• Number of ends down
• Ends down per 1000 spindle hours
• Mean duration of ends down
• Preset maximum number of ends down
• Number of spindles with ends down exceeding this limit
Measures of process control 209
Individual Spindle Monitoring (ISM) is one more system quoted

briefly here for the same purpose. It is developed by Rieter and working in
combination of ISM and SPIDER WEB. The system composed off the three-
stage light guide system. It leads personnel directly to the problem spindles
by means of signal lamp. First stage lid indicates machine-associated spindle
problem, second one for one particular spindle section (staff) consists of 24
or more spindles as per the make, and third one particular spindle facing the
problem. The system monitors and controls each and every spindle. Sensor is
provided on each spindle and detects whether runs, vibrates, slipper spindle
or ends down spindle etc. They are detected easily and quickly, hence help
in optimized working routes. So, routine patrolling and machinery audit
exercises get reduced. Thus optimized speed can be defined for the particular
mix or cotton quality on the basis of ends down rate. Productivity can be
enhanced by easily location and rectification of problematic spindle, provides
platform for the scientific comparison between different raw material batches
in spinning mill according to their performance.
Sensor-monitored drives developed on Saurer Zinser 351 ring frame.
It provides fine tuning of speed, twist and draft, essential for productivity
and quality of sophistically driven ring frame. It must be assured at all times
that the values set are actually realised across the entire long length of the
machine. Otherwise leads to count and twist variations within and between
bobbins. Thereby all speeds are sensor-monitored online and compared with
the actual motors speed and precisely readjusted on an ongoing basis in real
time.
Monitoring system for power failures is developed by Rieter. Hence,
power failure is synonymous with ends down. It results in loss of output, loss
of quality and human interference. The system consists of a monitoring system
to supervise power supplies. In the event of a power failure and regardless
of its duration, the spindle drive motor switches to the generator function
and supplies the other drives while they decelerate. In the case of power
interruptions lasting up to 2 seconds, the machine accelerates to operating
speed again without stopping. In the case of failures lasting more than 2
seconds, the machine decelerates in a similar fashion to a process-related
machine stoppage. This prevents ends down when the machine restarts.
Summarizing the entire discussion
The electronically controlled, sensor based monitoring and control system on
sophistically driven very long ring frame gives a reliable ground for easy and
precise way for process control. This is mainly attributed to
(i) The basic display on the operator edge shows the current machine
status at any time.
(ii) Soft keys provide direct access to the data displays important for
operation.
(iii) Microprocessor based analysis of data provides quick response to
address the problems.
(iv) The time until the next doffing process is indicated directly on the
basic display.
Thus optimization of process control system improves efficiency and the
allocation of personnel. Minimize human share and associated errors from the
production course.
15.4 References
1. http://www.rieter.com [Accessed on 24 October 2014]
2. http://www.rikipedia.com [Accessed on 24 October 2014]
3. http://www.lakshmimach.com [Accessed on 24 October 2014]
4. http://www.toyota-industries.com [Accessed on 24 October 2014]
Index
A Coriolis forces 172, 173

Advancement 122, 125 Cradle 24
Air drag 172, 173 Cradle Length 25
Angle of pull 79, 80, 160 Creel 5, 9
Angle of wrap 45, 151, 154, 162, C-Traveller 71, 82
172, 173
Angular speed 98, 164 D
Anti balloon device 54
Distance Clip 26
Anti-wedge ring 66, 83
Doffing 8, 143
Apron 5, 22, 23
Draft 15, 16, 40–43
Auto doffing 8, 145
Drafting 5, 14
Automatic material handling 204
Drive to drafting system 40
Dual motor drive 184
B Dual speed drive 184
Back winding 135,
Balloon collapse 98, 99
E
Balloon control ring (BCR) 54, 56,
130, 152, 157 Elliptical Traveller 71, 83
Balloon height 98, 99, 156, 168, End breakage rate 198
172, 179, 180
Bottom rollers 16
F
False draft 10, 12, 14
Fast boss 19
C
Flange width 60, 69
Center of Symmetry 68
Front roller overhang 155
Circle of Traveller 67
I Ring bobbin 119

Ring data system 204
Individual Spindle Monitoring 209
Ring diameter 60, 159, 161, 167, 189
Inverter motor drive 187
Ring design 57
Ring rail 5, 130
L Ring size 60
Lappet Guide 49, 51, 129, 151, 155, Ring Spinning 1
162, 165 Roller beam 6
Layering traverse 121, 123 Roller Buffing 21
Lift 99, 151, 160, 194 Roller cover hardness 21
Limiting speed of traveller 190, 197 Roller Setting 28
Loading of top rollers 30 Roller Stand angle 27, 151, 153
Long apron 24 Roving 3, 10
Loose boss 19 Roving stretch 10
Lubrication film 62 Running in 64
M S
Manual doffing 144 Saddle 33
Movable spindle rail 182 Scavenger Roller 38
Sensor monitoring drive 209
Separator 54, 55
O
Servo grip 141
Open creel 10, 13 Short apron 24
Orbit ring–traveller 66, 71, 86, 88 Shoulder heel 120, 184
Skewer 11
P Spacer 26
Package power 192, 195 Spindle 7, 104, 157
Piecing Efficiency 197 Spindle design 105
Pneumafil 38– 39 Spindle gauge 8, 159, 192
Production rate 159 Spindle speed 101, 108, 167, 196
Spinning 1, 2, 5, 164
Spinning angle 151
R Spinning Geometry 150
Regular creel 10 Spinning stability 101, 150, 159
Ring 5, 56 Spinning triangle 44, 152, 154
Index 213

Switching traverse 118, 124 V
Su-ring 66, 83 Variable speed drive 185
Vibrating string theory 97
T
Tangential belt drive 112 W
Tape drive 109
Wave length 98
Top arm 5, 31, 32
Top rollers 18 Wharve 106
Traveller 5, 66 Winding 5, 104, 114
Traveller canting 66 Winding diameter 180
Traveller mass 72.168, 172, 199 Winding force 166
Traveller speed 76, 83, 115 Winding on angle 76, 159, 175
Twist 49, 88
Twisting Mechanism 49
Y
U Yarn content 159
Yarn tension 163, 166, 180, 198
Under winding 131

(Woodhead Publishing India in Textiles) Bhattacharya, Someshwar S. - Shaikh, Tasnim N - Engineering Techniques of Ring Spinning-Woodhead Publishing India PVT LTD (2016)

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Engineering techniques of ring spinning

Dr. (Mrs) Tasnim N. Shaikh

WOODHEAD PUBLISHING INDIA PVT LTD

No claim to original U.S. Government works

International Standard Book Number-13: 978-93-85059-56-8 (eBook - PDF)

1. Introduction to ring spinning technique 1

2. Basic features of ring spinning machine 3

3. Design features of creel and drafting system variables 9

6. Winding mechanism 104

7. Builder mechanism 119

9. Spinning geometry 150

10. Yarn tension theory 163

11. Parameters influencing yarn tension during spinning 171

12. Means of controlling spinning tension variations 179

13. Optimization of ring spinning parameters 189

14. Material handling 202

15. Measures of process control 206

Several new techniques of spinning have been arrived in the commercial

to be studied thoroughly, like balloon theory, spinning geometry, yarn tension

1.2 Significance of ring spinning technique

fibers or even their blends. It is capable of spinning various categories of yarns

Abstract: Ring spinning is a versatile technique for spinning wide varieties of

2.2 Basic objectives

2.3 Working of ring frame

Figure 2.1 Working of ring frame

2.3.1 Creel section

2.3.2 Drafting section

2.3.3 Spinning and winding section

2.4 Skeleton structure of machine

Figure 2.2 Lengthwise bifurcation of basic frame work of ring

2.4.1 Manufacturing end

can be adjusted in height by screws, which facilitates leveling of the machine

Figure 2.3 Widthwise bifurcation of skeleton structure of ring

2.4.2 Head end

2.4.3 Tail end

assisting systems of the production mechanism, like the drive transmission

2.4.4 Doffing end

3.2 The creel

between 800 gm (conventional) to 3–3.5 kg (modern) at speed frame. So, the

3.2.1 Basic objectives of the creel

3.2.2 Types of creel

Figure 3.1 Regular creel

Figure 3.2 Regular creel skewer and roving bobbin

Limitations of regular creel: The regular creel is simple and robust in

vi. If a skewer is dropped due to careless handling, liable to burr up its

Figure 3.3 Bobbin overhead suspension pivot

The suspension pivot is composed of hollow aluminum cylindrical

3.3 The drafting system

and sliver, and simultaneously parallelizing its fibrous components, as it

Figure 3.4 3 Over 3, Double-apron top arm drafting system

The front drafting zone also known as major/main drafting zone, as

3.3.1 Bottom rollers

Figure 3.5 Type of bottom drafting rollers

distributed evenly throughout working area. Owing to its highest gripping

3.3.2 Top rollers

under an applied load. The basic engineering involved in their design is to

Table 3.1 Top – Bottom Rollers Diameters Used in the Industry.

Roller diameter Front Middle Back Bottom

Figure 3.6 Antifriction loose boss rollers

Antifriction shell-type rollers (Fig. 3.6), equipped with ball or needle

material involved is more. Drafting system on draw frame is provided

3.3.3 Roller buffing

3.3.4 Roller cover hardness