23 Ring 3

1
Optimising Spinning Ringframe Conditions

Key Main Machine Variables
Power consumption
End-breakage rate and yarn quality
Production rate
Balloon Control
Lift (balloon height)
Spindle Speed
Ring/Traveller
(Minimising unit cost, maintaining quality)
Maintenance costs
Production rate (kg/h)
N E
tex
Vd 60
1000
1
1000
N E
K
tex
n 60
1000
1 1
1000
5 . 1
tex t K =
t
n
Vd =
tex
K
n
=
K
tex n
=
tex
K
t =
N E
K
tex
n 60
1000
1 1
1000
5 . 1
Production rate (kg/h):
Increases with
Spindle speed n
Yarn tex
Machine efficiency E
Number of spindles N
Decreases with twist level K
Ring Spinning Production Calculation Example
Given:
Spindle speed: 18,000 rpm
Yarn linear density: 36 tex
Twist factor: 36 turnscm
-1
tex
1/2
Machine efficiency: 90%
Production rate: 100 kg/h
Calculate:
The number of spindles required.
The production rate of the machine
for a 9 tex yarn, all other conditions
remain the same.
Machine efficiency is affected by:
End breakage rate
Package size
Yarn tex
Spindle speed
End breakage rate is affected by:
Machine condition
Yarn strength (evenness, fibre, twist, tex)
Yarn tension (spindle speed, balloon size,
ring & traveller)
2
Spinning Tension Fs
Winding Tension Fw
Balloon Tension Fb
Friction Ff
Fs~Fb~Fw
Ring Spinning Yarn
Tension Analysis
Spinning Triangle
Front
Drafting
Rollers
To spindle
Main layer
(slow lifting of ring rail)
Ring Package (Cop)
Tube
Cross layer
(fast descending)
Package building
motion
Db
Bobbin
Traveller
Ring
Dr
Ff
Fc
o
Fw Sin(o) = Ff
2
2
Dr
V
m Fc Ff ~ ~
V
Sin(o) = (Db/2) / (Dr/2)
= Db / Dr
Fw = FfDr / Db
Db
V
m Fw
2
2 ~ V = ntDr
n
Fw
Db
n Dr
m Fw
2
) (
2

~
t
Yarn tension increases with

Traveller weight m
Square of ring diameter Dr
Square of spindle speed n
Yarn tension decreases with
Bobbin diameter Db
3
v = f
Basic Wave Equation
Given string tension T, string density (mass/length)
Wave velocity
T
v =
STANDING WAVES ON A STRING
Antinode
Node
L = /2
STANDING WAVES ON A STRING
Fundamental (First) Harmonic
/2
H
H < /2
v = f
= v/f
T
v =
tex
T
f
k
=
tex
T
n
K
H <
f = spindle speed n
= tex
For spinning
tex
T
n
K
H <
T > H
2
n
2
tex / K
Square of spindle speed
Yarn tension increases with
Square of balloon height
Yarn linear density
Problem: Higher tension increased yarn breakage
Solutions?
Reduce balloon size
Limit spindle speed
Not a problem for thicker yarns
Reduce balloon size
Smaller D
Lower H
Smaller Package
Higher Cost of Doffing
Lower Efficiency
4
H1
H2
Balloon Control
Tension Control: Traveller size
Minimum:
Stable balloon at
maximum package diameter and balloon height
Db
n Dr
m Fw
2
) (
2

~
t
T > H
2
n
2
tex / K
m > k H
2
tex Db/Dr
2
k H
2
tex/Dr
k depends on traveller/ring friction
No theoretical prediction, decided by trial:
Higher spinning tension better straightening &
parallelizing thus higher yarn strength, lower extension
Increase in yarn strength may be more than increase
in tension thus lower end-breakage rate
Better heat transfer
Smoother traveller running
Tighter package: easier to handle/longer yarn length
Heavier Traveller
With fixed spindle speed, increase delivery speed
(decreasing twist) until break. Traveller with highest
delivery speed at break can be used initially
Higher power cost (traveller motion, winding tension)
Traveller No.
(ISO) Guide
112 100 36
100 90 30
90 71 24
71 56 20
56 45 17
45 35.5 14
40 31.5 12
35.5 26 10
31.5 23.6 9
28 20 8
22.4 16 7
14 6
12.5 5.5
9 5
Synthetics / Blends Cotton Yarn Tex
(ISO No.=
g/1000 travellers)
ISO Traveller Number Guide
0
30
60
90
120
0 10 20 30 40
Yarn Tex
T
r
a
v
e
l
l
e
r

N
o
.
Cotton
Synthetics /Blends
5
Traveller and Ring Design
Max. Contact Area (heat transfer
& smooth running)
Low Centre of Gravity
Adequate Yarn Passage
Fibre / Yarn Requirement
Traveller and Ring Material
Low Heat Generation
High Heat Conductivity
High Wear Resistance (harder ring)
Steel + Surface Treatment (nickel, silver plating, chemical, etc)
Key Traveller Parameters
Traveller form (C, oval-flat, elliptical, N)
flat wire
Low yarn hairiness, for fine cotton / viscose yarns
semi-round wire
For blends, cotton and synthetics. Good
results with low twisted (knitting) yarn
ultra semi-round wire
For cotton, blends and synthetics. This wide profile
offers a large contact surface, for high speeds
flat round (combined profiles)
For acrylics, special synthetics and core yarn.
Flat toe, round yarn passage, for higher speed
flat round (combined profiles)
For acrylics, special synthetics and core yarn.
Flat toe, round yarn passage, for higher speed
semi-round high
Special section, designed for SU travellers
6
1. Spinning Power
Dependent on
Winding Tension
Yarn Rotation
Yarn Friction (traveller, yarn guide)
Traveller Motion
Yarn Tex
Balloon Height
Ring Diameter
Spindle Speed
Power consumption in ring spinning
2. Package Power
Dependent on:
Package Rotation
(air resistance, bearing friction)
Spindle Speed
Package Size (ring diameter, balloon height)
Higher balloon is more economical than larger ring
Power consumption in ring spinning
Primary Power =
Spinning Power + Package Power
Spindle Drive Efficiency (~40%) =
Primary Power 100
Primary Power + Transmission Loss
Building mechanism and drafting
system consumes about 10% of the
total power required
Ring Size
Doffing & Subsequent Handling
Piecing Frequency
Traveller (Spindle Speed)
Power Requirement
Capital Cost (Space & Machine)
Dependent on:
Count
Production rate
Utilisation factors
7
Front roller speed (lapping, piecing) (coarse yarn)
Spindle Speed
Production
Power consumption
Optimum is higher than physical limit
Traveller speed
(particularly for high strength cotton yarn)
Balloon tension (end-breakage rate)
(particularly for soft yarn)
Yarn damage (synthetics)
Minimum
Cost
Labour
Power
Capital
Material/
Auxiliary
Practical
Spindle
Speed
Unit Cost
Optimum Spindle Speed
Compact Spinning
Recent Developments
8
The Future of Ring Spinning ?
Most Versatile
Best Yarn Quality
Lower Operator Skill Requirement
Well Understood Technology
Large Installation Base
9

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1

Optimising Spinning Ringframe Conditions

Yarn tension increases with

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