By : Qasem Heydari, M. Sc. textile engineer, Polytechnic University, Iran
In spinning mills, yarn winding on cone process happens with various type of machines. Winder machines (cone winder and assembly winder) are one type of the yarn winding machines that are benefited in several spinning and weaving factories.
Undoubtedly, it is important to purchase our winder depend on our indeed and expect. For example, big size of winded cone for weft yarn is on focus for weavers.
Big variety of winders and sometimes, their low prices, make some factories to decide hastily to buy winder that is not suitable with other machines and there are not matching and appropriate between winder ability and case of use in those factories.
For instance, the main reason of low efficiency in most two-for-one twisting units is the weakness of winding machines and poor winded cone. In these cases, after a while, buyers discover this non-suitability and the winder machine abandon with no use and other winder is going to buy. In the otherwise, this non-suitability, burden many disorders and irregularity for the factory.
In this article, we investigated and sorted winder’s abilities and limits for kind of factories with various expects of winder to make easily deciding about the choice of a suitable winder for buy. At the end, winders’ technical necessities and additional options’ have explained.
Winders can have the following capability:
- Winded yarn on cone meter counter sensor, for whole heads of the machine, if winding of all heads occurs altogether, or separate winded yarn meter counter sensor for every head, or micro-switch for maximum package diameter and doffing size.
- Yarn fault (Thin, Thick and NEP) detector sensor or mechanical yarn fault (Thick points, the hairy pole on yarn and fluffy point and knot) recognition equipment, winding process stop mechanism, cutter, emitting of yarn faults mechanism.
- The ability of yarn plying and process stop when yarn loss each considered plies in a mechanical or electrical way, until 3 sensor or mechanical mechanism in each head.
- The ability of winding of reservation thread.
- Yarn waxing or oiling equipment, thermal, draft and texturizing process, mechanical, heat or wet splicing.
- Immediately Bobbin drives stop mechanism for roller or drum with minimum motor ramp or locking break shoes and escape for inhibiting of erosion of yarn on the drum.
- Tension applying on yarn for breakage and remove of thin and weak point.
- The separation between yarn tension and winding density.
- Adjustable package pressure with spring or air presser with the ability of easy up bring of the cradle and easily putting of bobbin and as far as possible separate opening and closing mechanism of bobbin from handle – using of 2 separate pistons for applying of pressure on package under drum and upbringing yarn package from drum while breakage happens– applying pressure on yarn package for inhibition of conical (sugarloaf) shape.
- The ability of loose and uniform winding – with using of feeder or balloon ring – open winding for dying or close winding (put several yarn rows next to each other) without a pattern – parallel, bias and crossed winding – more winding angle, more loose package – the separate opening of each yarn rows with next rows – constant winding angle or a constant number of helix winded on package in different package diameter.
- Random, precision or step-precision winding with grooved drum or cam traverse of traveller or traveller traverse motor.
- Applying steady tension on the yarn with use of disk and spring (its tension is not constant and depend on crossed yarn mass), disk with weight or tension gate – applying tension with use of crossing yarn over bar’s perimeter – tight winding for a dense package under full control.
- Regular winding in edge without falling (stitch yarn) – bobbin vibration absorption equipment – gentle holding of bobbin not tight and not loose – smooth winding of package with using of boll bearing or balls and cone or eye bearing For bobbin holder– suitable bobbin holding pressure with the use of suitable spring – using of high resistance allays for cradle don’t break anti-erosion lightweight anti-vibration without limp and swings, such as steel or Teflon or polyamide.
- Anti-patterning (anti-ribboning) with use of the sinusoidal change of cam or short time upbringing of package or make slippage between package and drum with motor short stoppage.
- Easy-open package, Conical for staple yarn, cylindrical for filament yarn, curve edge for dyeing yarn, multi-conical for weaving and pear-shape – more conic in bobbin end, accelerate conical angle – lose Travers in the edge.
The assortment of aspects of winding machines, and fitness between aspects and capabilities of winding machines:
Spinning mills benefit from winders as production of an intermediate product that will use in their needs at their mills or as final product for sell; some mills also buy winded yarn. All of these factories sorted at the following 10 groups. Other factories such as carded cotton spinning mills with yarn count thick than 30 or carpet weaving mills with low reed, don’t mention because of low sensitivity in finding suitable winder.
Winder’s technical necessity:
- Suitably polished counting (ceramic) for non-erosion and twist opening in touch within drum with high rotational Speed – filament yarn has low friction Constant and have low luck to jump out of drum track.
- Precise drum design in aim to creating of tight edge because of zero speed of yarn indirect change in edges – suitable deep for constant tension in certain yarn length in meddle and asides.
- Strong and high resistance allay from iron, aluminium, cast iron, Teflon and plastic.
- Poly-time motor high power low energy consumption with suitable rotation per minute – suitable aluminium or polyamide allay in ceramic yarn guide and bobbin holder cradle.
- Thick sheet and jointing chaise with screw instead of wedding, mechanized sheet cutting with CNC or casting of the heavy chaise and sanding precise jointing point, designing of chaise with more curve for more strong and low vibration and applying of big bearing and strong for low drum vibration – high-quality bearing and strongest cradle handle – shaft with suitable allay and diameter and coupling.
- Durable Lasik body colour
- Heads designing with the ability of easy service and maintenance and easily lot changing parameter change like easily change of drum.
- The suitable number of electronic board, controllers (PLC) inverters and drives and type of electrical segment’s jointing together. Kind of consumption electricity consumption (1 phase or 3 phases) with low ampere and low watt.
- Constant non-precision winding (accelerative for conical bobbin for unfirming in bobbin length) tension adjust according to precision winding speed and increasing of package diameter and winding speed.
- Winding angle more than 81 cause fall. Less than 68, cause yarn summation in middle
More winding speed
- High maximum weight and diameter of winded package
- Recognition sensor in Travers path for inhibition of jumping of yarn on drum and winding on drum perimeter.
- Laborance (how much labor need), how putting of bobbin on creel and way of doffing and pick up of winded package (vertical or horizontal), ergonomic and way of machine operation.
- Separate winding motor for each heads and separate traverse motor for each head
- Sharp or smooth package edge
- Adjustable cone length ( 17-23-29 centimetre)
- Adjustable conical edge
- The capability of using of conical and cylindrical cone
- Operation status display lights
- Production monitor for display and counter of shift product and number of doff and efficiency and machine settings
- Operator and status operation change switches and bottoms