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Yarn tension (traveller drag, balloon) Traveller speed Heat Draft system
Economic
Large package size required (fewer knots, fewer replacements) but larger package requires more power to drive and faster traveller speed Cause of Problem: Twist Insertion Requires Package Rotation
Static Yarn
Twisting
Twisting
Smaller mass involved in twist insertion higher speed Break in Fibre Flow No spinning balloon lower yarn tension Twisting Package formation independent from twisting larger size, choice of form, reduced winding
Winding
Brief History of Open-end Spinning Development 1876, J Hibry 1937, Svend Ejnar Berthelsen
Brief History of Open-end Spinning Development 1876, J Hibry 1937, Svend Ejnar Berthelsen 1955, ITMA Brussels, Spinnbaus Meimberg eMKa-Spinner
Brief History of Open-end Spinning Development 1876, J Hibry 1937, Svend Ejnar Berthelsen 1955, ITMA Brussels, Spinnbaus Meimberg eMKa-Spinner 1960s, Intensive R/D in many countries
Brief History of Open-end Spinning Development 1876, J Hibry 1937, Svend Ejnar Berthelsen 1955, ITMA Brussels, Spinnbaus Meimberg eMKa-Spinner 1960s, Intensive R/D in many countries 1965, KS 200, the first machine with drafting rollers exhibited in Czechoslovakia 1966, BD200 installed in factory 1967, ITMA Basel, Switzerland, Elitexs BD200, 30,000 rpm
BD200b
Brief History of Open-end Spinning Development 1876, J Hibry 1937, Svend Ejnar Berthelsen 1955, ITMA Brussels, Spinnbaus Meimberg eMKa-Spinner 1960s, Intensive R/D in many countries
Common requirements of open-end spinning Fibre separation device Means of fibre transportation Device for collecting separated fibres
1965, KS 200, the first machine with drafting rollers exhibited in Czechoslovakia 1966, BD200 installed in factory 1967, ITMA Basel, Switzerland, Elitexs BD200, 30,000 rpm 1971, ITMA Paris, wide spread commercial introduction 2003 8m rotors 174.5 m ring
Device for rotating open-end of yarn (twisting device) Yarn take-off and package build mechanism Key feature of open-end spinning: Separation of twisting from winding, but continuous operation
Yarn Delivery
Sliver
Trash
Opening Roller
Rotor
Nozzle
0.015
30
100
200
2.5
Draft
2000
1/80
20,000
10
1.5
120
Yarn Arm
Yarn Twist
Yarn Arm Rotation Ny (rpm) Nozzle
t = Nr Vd
Back Doubling: t D
Vd = (Ny-Nr) D Vd Ny = Nr + D t= Nr Vd Nr Vd + 1
Yarn Peel-off Point Moving Relative to Rotor = Yarn Delivery Speed Vd (m/min)
Vd
D Ignored
Nr Ny-Nr Rotor Diameter = D (m) Nr Vd D Nr D Vd tD
Vd
t=
Back Doubling:
Thousand RPM
120 100 80 60 40 20 0 1967 1972 1977 1982 1987 1992 1997 2002 2007
Rotor Diameter D
160000
Smaller rotor Higher speed
0 28 32 36 40 44 48 52 56 Rotor D (mm)
Groove Angle
: 30-60o
Thicker yarn: Larger D &
Rotor Diameter D
If opening roller speed is too high, fibre striping by air may not be complete, leading to more yarn faults
Rotor Groove
Opening Roller Type Type of wire (pin or saw-tooth) Point density Working angle
Working angle
Pin Type
Saw-tooth Type
Draw-off Nozzle
Steel draw-off nozzle:
For man-made fibres and blends No static charging Lower surface nozzle temperature
Grooved nozzle increases false twist, helps to spin yarns with lower machine twist (e.g. knitting yarns)
Yarn rolling against stationary nozzle surface Stationary Draw-off Nozzle Effects of Draw-off Nozzle surface
Grooved nozzle increases false twist, helps to spin yarns with lower machine twist (e.g. knitting yarns) Grooves disrupt fibres in yarn, increasing hairiness and yarn faults
Grooved nozzle increases false twist, helps to spin yarns with lower machine twist (e.g. knitting yarns) Grooves disrupt fibres in yarn, increasing hairiness and yarn faults Higher false twist increase wrapper fibres during untwisting by nozzle
Fibre straightening and parallelization by drafting Fibre under tension through the process
Spinning Triangle
To spindle
Fibres deposited first (towards the core) has higher twist Fibres are twisted under low tension: low fibre straightness Twist differential & wrapping fibres make twisting testing difficult
Fibres near core has lower twist angle & under lower tension
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Ring Spinning and Rotor Spinning Comparison Ring Spinning and Rotor Spinning Comparison Raw material requirements Techno-economics
Investment Fixed costs
Labour Energy Product value Application Fibre type Yarn type and end-use
Machine Example
Rieter R 40
Material cotton, man-made fibres and blends up to 60 mm Feed weight 7.00 to 2.5 ktex Draft 40 to 400 Yarn count 200 to 10 tex Twist 196 to 1500 T/m Package weight max. 6 kg (max. 350 mm ) Rotor 28, 30, 31, 33, 36, 37, 40, 41 46, 47, 48, 56, 57 mm
Small bobbin Opening rollers 64 mm High doffing frequency (lower efficiency/higher labour cost Draw-off nozzles ceramic in various designs
Rotor Spun Fancy Yarns Limited to fibre effects (mainly slubs) Variable motor driven sliver feed
Difficult to produce abrupt changes Minimum length D due to back-doubling
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Core Yarn
Cover Yarn
Staple Yarn
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