TT3351 PREPARATORY PROCESS FOR WOVEN FABRIC MANUFACTURE LTPC Upon completion of the course, the students will

Upon completion of the course, the students will be able to

3024 CO1: Explain the types of winding, yarn faults and automatic winding
OBJECTIVES: CO2: Elucidate winding package faults and winding performance
 The main objective of this course is to enable the students to understand the preparatory processes CO3: Discuss the types of warping and sizing process
involved in the production of fabrics. CO4: Describe the process control in warping and sizing
CO5: Explain the manual and automatic drawing in process
UNIT I WINDING 13 CO6: Analyse yarn faults and control of faults in cone / cheese finding
Objects of winding; principles of cheese and cone winding machines; drum and precision winding; CO7: Understand the preparatory process of fabric manufacturing by practice.
uniform build of yarn package; types of drums – half accelerated and fully accelerated drums; control of
balloons; Classification of yarn faults and its removal; concepts in yarn clearing – mechanical, optical and TEXT BOOKS:
electronic clearers; knotters and splicers, weft winding; study of modern automatic winders. 1. Sriramlu P.K., Ajgaonkar D.B. & Talukdar M.K., "Weaving Machines: Mechanisms, Management",
UNIT II PROCESS CONTROL IN WINDING 5 Mahajan Publishers, Ahmedabad, 1998.
Faults in wound packages, their causes and remedies; winding synthetic and blended yarns; winding for 2. Lord P.R. and Mohammed M.H., "Weaving – Conversion of Yarn to Fabric", Merrow Publication,
colouration; quality of knots and splices; winding performance; productivity; maintenance; quality control; 1992.
material handling.
UNIT III WARPING AND SIZING 18 REFERENCES:
Objectives of warping, material flow in beam warping and creels used in warping machines; sectional 1. John A. Iredale “Yarn Preparation: A Hand Book”, Textile Institute, Manchester, 1992, ISBN:
warping machines. Sizing objectives of sizing; sizing materials and recipe used for different types of 1853390429
fibers; size preparation equipment; sizing machines; sizing filament yarns; concept of single end sizing, 2. Lord P. R. and Mohamed M.H., “Weaving: Conversion of Yarn to Fabric”, Merrow, 1992, ISBN:
combined dyeing and sizing. Control concepts in modern sizing; energy conservation in sizing; Sizing 090409538X
defects and production calculations. 3. Ormerod A. and Sondhelm W. S., “Weaving: Technology and Operations”, Textile Institute, 1995,
UNIT IV PROCESS CONTROL IN WARPING AND SIZING 5 ISBN: 187081276X.
Process control in warping (production calculation, machine and labor productivity, control of end breaks,
quality and hard waste in warping); Control systems used in sizing machine.
UNIT V DRAWING- IN 4
Need for drawing-in operation; manual and automatic drawing- in, leasing, knotting and pinning
machines; selection and care of reeds, healds and drop pins, control of cross ends and extra ends and
calculations.
TOTAL: 75 PERIODS (45L + 30P)
LIST OF EXPERIMENTS:
1. Analysis of Yarn faults
2. Control of production, package density, yarn faults in cone / cheese winding machine
3. Study of pirn winding
4. Study of warping machine
5. Study of sectional warping machine
6. Study of drawing – in, denting and tying
OUTCOMES:
Unit I
Angle of cone for Warping - 3 30’, 55’, Angle of cone for Dyeing - 430’
1.1.2 Objective of Cone Winding Angle of cone for Knitting - 915’, Angle will vary according to the requirements.

1. To transfer yarn from small packages like spinning cops, Doubler cops, hanks to large packages like For knitting machines, initially the angle of cone is 915’ and the final angle is 14. As the

cones or cheeses or spools. diameter of package increases, the taper also gradually increases up to the full size. These

2. To remove objectionable yarn faults like slubs, neps, thick & thin places, etc., present in the yarn. packages are called as ‘Foster cones’ or Accelerated Cones’. These cones facilitate easy
withdrawal of yarn in knitting machine and so yarn breakages are reduced in knitting machines.

Advantages of rewinding yarns:

Cones or cheeses contain longer length of yarn. So the following advantages are obtained in the 4. Angle of wind: α
succeeding machines. It is the angle between yarn on the surface of the
a) Numbers of piecing are reduced package and a line drawn perpendicular to the axis
b) Production and efficiency of the machines are improved of the package. (or) Inclination of yarn to the
c) Quality of cloth is improved vertical is called ‘Angle of wind’.
d) Waste % is reduced
e) By removing objectionable faults in the yarn, quality of cloth is improved 5. Number of winds:
1.1.3 Terminologies related to Cone winding The number of winds may be defined as the number
DRUM
1 Traverse: of rotations made by the package (cone) for one
Laying of yarn from one side to another side of the stroke of traverse.
package. Length from LHS to RHS of the traverse Ex: No. 2½ wind means 2½ rotations are made by
is called traverse length. the package for one stroke of traverse.
6. Wind ratio:

2. Double traverse: The ratio between the linear traverse speed of yarn and the speed of yarn due to package rotation.

Laying of yarn from LHS to RHS and then from The wind ratio W is given by, Tan α = T / π D W, where

RHS to LHS. It is two stroke of traverse. α = Angle of wind,

T = Traverse distance at any moment
D = Cone instant diameter
W = Wind ratio

3. Angle of cone: θ 1.1.4 Principles of winding:

It is the angle between the side and axis of the cone. According to the method of package drive, basically there are two principles involved in winding

Angle of cone influences the unwinding of yarn machines. They are

from the cone. 1. Precision or spindle winding type

2. Drum winding type

1. Precision or spindle winding type:

 Constant yarn speed is difficult and
5 Constant yarn speed is achieved easily.
expensive.

6 Mechanically complicated. Not complicated.

Separate traverse mechanism No separate traverse because of rotary

7
required. traverse.
In this type, package is driven directly by means of a spindle. The packages are mounted on a spindle and
are driven by a motor. Traversing is carried out by means of a thread guide with a traversing arrangement. Used only for specific purpose like
Most commonly used on all modern
Yarn is wound by rotating the package and traversing is done by traverse guide. 8 synthetic filaments or costly staple
winding machines
2. Drum winding type: yarn

9 Produces close wound package Produces open wound package

Angel of wind is decreasing with the Angel of wind is constant from empty
10 increasing in diameter of the package to full package
In this type, package is driven by surface contact with a drum. The package is mounted on a holder which
package
is made to rest on the drum surface. When drum rotates, the package is also rotated due to the surface
contact and the yarn is wound. The grooved drums are used for both winding and traversing the yarn. Package stability and density is less
11 Package stability and density is more
Hence the drums are called “rotary traverse drums”.

COMPARISON BETWEEN PRECISION TYPE AND DRUM TYPE WINDING MACHINES

1.1.5 Types of Packages

No PRECISION TYPE DRUM TYPE
In winding machines two types of packages are used. They are

Package is negatively driven by 1) Supply packages 2) Delivery packages.

1 Package is positively driven. 1) Supply Packages: These are packages supplied from spinning machine or doubling machine or
frictional contact.
Reeling machine. Examples: i) Spinning cop (ii) Doubler cop (iii) Hank
Package rpm remains constant from Package rpm decreases continuously 2) Delivery packages:
2
empty to full package. from empty to full package. These are the packages produced by winding machines.
Examples: i) Double flanged bobbin (ii) Cone (iii) Cheese or spool
The yarn take-up by the package Advantages of using cones, Cheeses and Spools:
The yarn take-up remains constant
3 continuously increases in proportion 1) Cones contain longer length of yarn; hence production and efficiency of succeeding machines are
throughout the build of the package.
to its diameter. improved.
2) As the impurities like slubs, neps, thick & thin places are removed, quality of yarn and fabric are
The number of coils per traverse The number of coils per traverse improved.
4 remains constant at all stages of continuously decreases as the package 3) In shuttle less looms, cones are directly used as weft packages and so pirns are eliminated.
package. diameter increases.
Types of winds: There are two types of winds commonly used they are
i) Open wind and ii) Close wind The Slub catcher is having blades which are set according to the Count (or) diameter of yarn. The
Open wind: In this type of wind, succeeding coils of yarn are laid widely objective of Slub catcher is to remove slubs, neps and thick places present in the yarn. The yarn is then
on the preceding coils of yarn. As the coils are laid widely, this package is passed over broken thread stop motion wire (D). When an end breaks (or) the yarn in the supply cop
suitable for dyeing, high speed warping machines and in knitting becomes exhausted the stop motion raises the cone from the winding drum.
machines. These packages are produced by drum winding machines. Finally the yarn is passed through the grooves of the winding drum (E) and on to the paper cone. The
Close wind: In this type of wind, the succeeding coils of yarn are laid drum shafts are provided with ball bearings to get smooth rotations. The drum shaft is driven by a motor.
very closely on the preceding coils of yarn. As the coils are laid closely, The drum surface wind the yarn over paper cone and the grooves in the drum traverses the yarn across the
the package density is more and also the stability of the package is good. paper cone. Since the winding and traversing is carried out simultaneously by the drum, the drum is called
So this package is suitable for sewing machines. These packages are Rotary traverse drum. The shape of cone depends on the shape and depth of grooves.
produced by precision winding machines. The paper cones are made of hard paper and are mounted on cone holders (F). When the level of yarn
wound on the cone touches the ring (G), the winder will remove the cone from cone holders. The machine
is further fitted with conveyor to carry empty cops and the cops are deposited on to a suitable container
Passage of Yarn through a High Speed Drum Winding Machine (non automatic)
kept at the end of the machine.
A – Spinning cop
Precision cone and cheese winding machine:
B – Tensioner

C – Slub catcher A - Creel

B - Spinning cop
D – Broken thread Stop motion wire
C - Balloon breaker
E – Grooved Drum D - Yarn guide
E - Gate type of tensioner
F – Cone holder
F - Slub catcher
G – Full cone feeler ring G - Broken thread stop
motion
H – Thread guide
wire
J – Cone H - Yarn guide
I - Traversing guide
K- Cone drum shaft
J - Traversing Cam
L – Balloon breaker K - Cone shaft
L - Cam wheel
M - Cone shaft driving pulley
The supply package in the form of spinning cop (A) is mounted on a peg on the creel. The creel consists
of a horizontal rod extends to the entire length of the machine. At regular intervals according to number of
drums, numbers of pegs are mounted. The yarn from the spinning cop is first passed through the Balloon The main feature of precision winder is the spindle in which the package is mounted and it directly gets
breaker (L). The objective of the Balloon breaker is to break balloons touching with each other when drive. The types of wind that can be produced on this machine are close wind and open wind.
unwinding is carried out. Then the yarn is passed through Tensioner (B), which gives required tension to
The spinning cop (B) is mounted on a peg in the creel rod (A) extending to the full length of the machine.
the yarn for proper unwinding. The yarn is then passed through Slub catcher (C).
The yarn from the spinning cop is first passed through the Balloon breaker (C). The objective of the
Balloon breaker is to break balloons touching with each other when unwinding is carried out. Then the
yarn is passed through Gate type of tensioner (E), which gives required tension to the yarn for proper range of ‘yarn faults’ and correspondingly a further reduction in the frequency. Yarn defects have sizes
unwinding. The yarn is then passed through Slub catcher (F). from +100% and larger and lengths of 1 mm and longer.
The objective of Slub catcher is to remove slubs, neps and thick places present in the yarn. The yarn is
then passed over broken thread stop motion wire (G). When an end breaks (or) the yarn in the supply cop
becomes exhausted the stop motion raises the cone from the winding drum. Then the yarn is passed
Classification of Yarn Faults / Defects
through a yarn guide (H) and a traversing guide (I) and wound over paper cone.
Yarn faults are mainly categorized as below:
The slotted cam (J) is fully enclosed in an oil box to keep it lubricated all the time by splash of the oil. The
winding speed of the machine can be adjusted from 200 to 400 yards per minute to suit yarns of different A. Frequently Occurring Faults (Analyzed by Uster Evenness Tester)
qualities and counts. The spindles are located in horizontal position and get drive from individual motor. B. Seldom Occurring Faults (Scanned by Uster Classimat Tester)
The spindle rotates at a constant speed and hence when the package diameter increases, the yarn tension
also increases and may result in an end breakage. To avoid build-up of tension in the yarn, tension of yarn A. Frequently Occurring Faults:

is reduced as the diameter of the package is increased. These are faults occurring in the range of 10 to 5000 times per 1000 m of yarn. Yarns spun from staple
fibers contain imperfections, which can be subdivided into three groups:

Yarn Faults / Defects: 1. Thick Places

A yarn which is not uniform is said to be irregular or to contain yarn defects or faults. These faults vary in 2. Thin Places

their cross-sectional size and length. Yarn quality is influenced by various types of yarn faults which also 3. Neps

affects the quality of fabric produced. During the yarn manufacturing process various types of
Thick places: Cross-sectional size +30% to +100% of normal yarn with fault length ranging from 4 to 25
irregularities are generated in the yarn diameter regularly or at intervals which are known as yarn faults.
mm.
Yarn faults are represented based on their size, length and their frequency of occurrence.

 Unevenness or irregularity
 Imperfections
 Objectionable yarn faults

“Unevenness” or “irregularity”
In all staple spun material (yarn, rovings and slivers), the fiber distribution along the material varies. The
mass per unit length variation due to variation in fiber assembly is generally known as “Irregularity” or
“Unevenness” (in practice the Um% or CVm% value). It is the skill of the spinner to arrange all machine
settings in such a way that all fibers are spread as even as possible over the length of the material.

Imperfections
The extremes of variations, i.e., the thin places, thick places and neps, are usually referred to as
Fig: Thick and thin places in yarn
“Imperfections”. These “imperfections” are determined according to a frequency figure or number per
1000 m or yards. Thin places: Cross-sectional size -30% to -60% of normal yarn with fault length ranging from 4 to 25
mm.
Objectionable yarn faults
If one now considers faults larger than +100% based on the mean yarn cross-section, one moves into the
Neps: Neps are defined as small, tight balls of entangled fibers seen in linear textile strands. Cross- These are the thick and thin places in yam which occur so rarely that spotting them would require testing
sectional size +140% to +400% of normal yarn with a fault length of 1 mm. at least 100,000 m of yarn. These faults may be classified further into the following types:

1. Short thick places: 1 to 8 cm and above +100%

2. Long thick places: Above 8 cm and above +45%
3. Long thin places: Above 8 cm and less than -30%

Fig: Neps in yarn

Thin and thick places are produced due to drafting irregularities and neps are generated due to immature
fibers in raw material.

B. Seldom Occurring Faults:

Fig: Spun in fly

1. Slubs
Objectionable yarn faults can be categorized in three groups:
2. Spun in fly
3. Long thin places 1. Faults due to raw material
2. Faults due to piecing
3. Faults due to Spinning machine

1. Faults due to raw material: The number of objectionable faults due to raw material varies from 16%
to 30% with different yarns.

2. Faults due to piecing: The number of objectionable faults due to piecing varies from 9% to 16% of the
total objectionable faults.

Fig: Slubs in yarn

 1.3.3 Passage of yarn through an Autoconer (SCHLAFHORST AUTO CONER 238)

A - Spinning cop

B - Balloon breaker

C - Pre cleaner

D - Tensioner

E - Splicer

F - Electronic Yarn clearer

G - Cut clamp device

Fig: Bad piecing H - Yarn Trap

3. Faults due to spinning machine: The spinning frame (R/F) is responsible for about 50% to 60% of the I - Drum
total objectionable yarn defects.
J - Cone

Remedies of Yarn Faults: K - Waxer

1. Machine surfaces to be maintained clean. The supply package in the form of Spinning Cop (A) is kept on a peg in the creel. Yarn from the cop is
2. Broken teeth gear wheel to be avoided and proper meshing to be ensured. passed through balloon breaker (B) and Pre cleaner (C). The object of balloon breaker is to avoid snarls or
3. Setting at ring frame to be maintained. loops formation. The pre cleaner is used to remove adhering impurities. The yarn is then passed through
4. Removal of foreign matters (such as jute fibers, color cloth bits) to be ensured during preparation of tensioner (D) and Splicer (E). The tensioner consists of two discs and the discs are rotated by a motor.
mixing.
The advantage of positively driven tensioner is less wear & tear and even tension control. The object of
5. Better fiber individualization at cards to be achieved.
splicer is to join two broken ends pneumatically in the event of yarn breakage or cop exhaustion. The yarn
6. Correct tension weights and slub catcher settings to be employed at winding.
is then passed through Electronic yarn clearer (F) and cut clamp device (G). The function of Electronic
7. Optimum twist to be used for the type of cotton processed.
Yarn Clearer is to remove slubs, neps and thick places present in the yarn. Here the clearing efficiency of
8. The yarn to be conditioned.
this clearer is 80% and yarn abrasion is reduced. Cut clamp device is used to catch the broken end during
9. Vibration of bobbins on the spindles to be avoided.
splicing.
10. Use of optimum roller settings.
11. Optimum top roller pressure to be maintained. After this the yarn is passed through waxing unit (K), yarn trap (H), groove drum (I) and finally on to the
12. Use of travellars of correct size and shape and rings in good condition to be ensured. cone (J). The waxing unit is used for hosiery cones. As the yarn passes through the waxing unit, a wax
13. Optimum relative humidity to be maintained in the spinning room. coating is applied on the yarn.

This improves yarn qualities like smoothness and uniformity suitable for knitting machine. The yarn trap
suction tube is used to during splicing operation. The grooved drum is used to wind and traverse the yarn
on the cone.
This machine is a single sided machine normally about 60 winding positions. Spinning cops are fed by a iii) It monitors the data
magazine and the exhausted cops are delivered by a conveyor to a sorting table. A doff master is provided
Slub Catchers (OR) Yarn Clearers
to doff the cones. The machine runs at 1500 meters per minute.
Yarn clearer is a device which is used to remove faults (thick places, thin places, foreign matter
1.3.4 Special features of SCHLAFHORST AUTO CONER 238
etc.) from the yarn in order to increase the yarn quality and weaving efficiency. This device is
mainly used in winding steps.

1. Machine Speed: The machine runs at a delivery rate of 1500 meters per minute Slub Catchers (OR) Yarn Clearers

2. Tensioner: A positively driven tensioner discs are provided. Objective:

3. Splicer: The splicing unit consists of an intermingling chamber, in which the broken ends are placed The objective of using Slub Catchers is to arrest the slubs, neps, big knots and thick places
in overlapping manner. Then a jet of compressed air untwists and twists the broken ends together to present in the yarn.
form the yarn strand.
These faults are called as objectionable faults. If these faults are not removed they will
4. Electronic yarn clearer: This clearer eliminates slubs, neps, thick & thin places. cause either yarn breakages in the next machine or will be seen as prominent fabric defects.

5. Waxer: A positively driven waxing unit is provided. Waxing is done especially for knitted yarns Different Types of Yarn Clearer:
which improve yarn strength, smoothness and uniformity. There are two types of yarn clearer

6. Drum: Each winding drum is driven by a separate motor and controlled individually. The motor can Mechanical yarn clearer
be reversed during mending a broken end.
Electronic yarn clearer
7. Anti patterning device: This device engages and disengages the drum drive at regular intervals.
A. Mechanical yarn clearer:
Hence the required slippage in obtained to avoid patterning or ribboning. (The patterning or ribbon
formation (Ribboning ) can be defined as a yarn package defect to be occurring during yarn winding • Conventional manual-type winding machines are normally equipped with mechanical type clearer.
process, in which the yarn coils get laid on the top of the previous yarn coil').
• Mechanical clearer basically consist of an adjustable slot through which the yarn passes.
8. Auto doffer: The auto doffer replaces the full cones with empty cones. The length of yarn on the full
• It traps only thick places that are greater than the slot setting.
cone is selected in the monitoring control system.
• The device incorporates a cutting edge that breaks the yarn faults.
9. Magazine: The magazine consists of 6 pockets to hold 5 Spinning cops. Whenever it is required to
change the empty cop, the magazine rotates and a cop is transferred to the peg in the creel. The empty • Mechanical clearers are rarely used nowadays as they are not efficient in removing thin places and
cop is ejected on to a conveyor running behind the creel which deposits the empty cops on a sorting contaminants.
table.
Types of yarn clearers:
10. Suction unit: Each winding unit is fitted with suction duct to keep parts free of dust and fly.
• Mechanical type:
11. Monitoring information control system: This system is incorporated with a report print out. The • Fixed blade type
system has the following features. • Movable blade type
• Swinging blade type
i) It registers the production data like drum speed, efficiency etc

ii) It controls the production data

Fixed blade type: This is based on casting a shadow of yarn on the photo electric surface. If there is any fault in the yarn
like slub, nep, thick place and big knots, the shadow falling on photo electric surface is affected and hence
a signal is generated which in turn actuates the knife to cut the yarn.
In this type, the yarn is passed between two fixed blades. The gap
between the blades is constant and can‟t be changed which is the Working of Photo electric type of Slub Catcher
disadvantage of this system. We cannot use this blade for all count A lamp is illuminated from one side and the light rays fall on the Photocell placed on the other side and
yarns. the yarn passes in between lamp and photocell. If there is no fault in the yarn then the reflected rays from
light will be same. If there is a fault like slub, nep, thick place and big knot then the reflected rays from
light source is affected. This causes a change in the current through the Photo electric device. The change
Movable blade type:
in current causes a generation of a signal and the signal is amplified and send to a discriminator, which
In this type, the yarn is passed between the fixed and movable
takes into account of both length and magnitude of variation. If the variation exceeds the limit of fault size
blade. The distance between the blades can be altered by a screw
which is preset, then knife actuated to cut the yarn.
adjustment in the movable blade. This type of yarn clearer is
suitable for all count of yarns. If the fault size is less than the preset fault size the knife is not actuated. The sensitivity is set by a knob
and if the signal voltage generated by a fault in the yarn exceeds the reference voltage the knife is actuated
to cut the yarn.
The disadvantage of this type is that sometimes the flattened slubs (or) neps may pass through.

Swinging blade type:

In this type, the yarn is passed between the platform and

swinging blade. The swinging blade is fixed on the head and
supported by a pivot. The swinging blade is given a small
pressure by a spring. Hence this swinging blade gives a small
tension to the yarn. The swinging blade is of different categories
namely plain edge blade, serrated edge blade, heavy blade and
light blade.

Electronic Yarn Clearers (OR) Electronic Slub Catchers

In order to get superior quality fabrics, yarn has to be completely free from objectionable faults. This Capacitance type of Electronic yarn clearers
cannot be achieved by using Mechanical Slub Catchers. The principle of Electronic Yarn Clearers is a Principle of Capacitance type Slub Catcher:
continuous measurement of size of the running yarn. Measurement is made both with reference to length Yarn is passed between two metal plates called Capacitance. If there is change in diameter of yarn there is
and mean cross sectional area of yarn. a change in Capacitance value. If the Capacitance value exceeds the preset value, then the knife is actuated
to cut the yarn.
There are two principles involved in Electronic Slub catchers and they are: The device consists of two metal plates separated by a small air gap. The yarn is passed in between the
1) Photo electric type and 2) Capacitance type two Capacitance plates. If there is no fault in the yarn then there will not be any change in the Capacitance
value. If any slub, big knot, thick place and nep passes, the Capacitance value changes accordingly and
Photoelectric type of Electronic yarn clearers hence an electrical signal is generated. The signal is fed to amplifier and the amplified signal is send to a
Principle of Photo electric type Slub Catcher
discriminator, which takes into account of both length and magnitude of variation. If the variation exceeds vi) In both photoelectric and capacitance type, the proper functioning of device is affected by the
the limit of fault size which is preset, then knife actuated to cut the yarn. accumulation of flying fibers in the scanning slot.
If the fault size is less than the preset fault size the knife is not actuated. The sensitivity is set by a knob
and if the signal voltage generated by a fault in the yarn exceeds the reference voltage the knife is actuated Objective of Tensioner:
to cut the yarn. The capacitor is very sensitive to moisture. So a fiber type dielectric control is used for the  To control the package density, by giving the required tension on the yarn
moisture according to the type of fiber. It is graduated from 1 to 8 and can be set according to moisture  To remove weak places, by giving tension weight on the yarn. Because of tension weight weak
content of the fiber when processing. places are broken while passing through the Tensioner
Yarn  To remove the adhering impurities present in the yarn. This is achieved by the centrifugal force
created during high speed unwinding through the Tensioner
Slub
Types of Tensioner:

Fiber control Di-electric There are two common methods of applying tension on the yarn.
Oscillator
Additive method and Multiplicative method
Additive method of tensioners
Amplifier
In additive method, the yarn is passed between a roller and a plate or in between discs which are weighted
by dead weights or springs or electromagnets. In this method, the following types of tensioners are used.
Slub size discriminator Sensitivity control a) Washer type
b) Disc type
c) Combined washer and disc type
Knife actuator
d) Disc and spring type

Merits of Electronic yarn clearers:

i) Easy to set a) Washer type:
ii) Setting is accurate and time consumption for setting is very less
A – Washer B – Plate

iii) Yarn clearing efficiency is 70% to 80%

iv) Yarn is not making any physical contact with the clearer, so yarn quality is preserved and abrasion is It consists of one or two polished metal washers and the yarn is passing in between washer and bottom
avoided plate. Weight of washers and hence the tension acting on yarn will vary according to the Count of yarn.
v) Knot factor is only 1.7. The tension is developed due to the friction between the washer, plate and yarn. Heavier washers are used
for coarse yarns and lighter washers are used for finer yarns.
Demerits of Electronic Yarn Clearers:
i) In photoelectric type, external light source may affect the accuracy of the device.
ii) In photoelectric type, detection of faults depends on the intensity of the light source. Hence b) Disc type:
the intensity of the light source should be maintained constant.
A, B – Discs D – Yarn
iii) In capacitance type, capacitance value is influenced by the humidity in the atmospheric air.
Hence there may be variations in the identification of faults.
In this type, two highly polished metal discs are mounted on a short spindle one over the other. Yarn is In this type, two discs are used. Top disc carries a spring on a stud with a nut arrangement. By using the
passed in between these two discs. Due to the friction between yarn and discs, tension is applied on the nut; spring can be compressed or expanded. If the spring is compressed, more friction is imparted in the
yarn. Top disc is changed to apply tension according to the count of yarn processed. Heavier discs are used yarn and so more tension is applied. In some machines, a knob with a dial is provided to know the correct
for coarse yarns and lighter discs are used for finer yarns. setting of tension according to the yarn count processed.

c) Combined Washer and Disc type Merits of additive type of tensioners:

A – Disc 1. Easy threading
2. Tension variation in the yarn is not multiplicated.
B – Washers
3. In Autoconers, the top disc is positively rotated so that the wear and tear of disc is prevented and also
C – Spindle it provides cleaning action.
Demerits of additive type of tensioners:
D – Yarn
1. The yarn may come out of the tensioner if any deflection takes place during running
E – Spare 2. Thick places in the yarn will forces the discs apart thus causes interference in the tension application
washer
Multiplicative method:
In this type, two discs are mounted on a spindle which is in inverted ‘U’ shape and the top disc carries
In multiplicative method, yarn is deflected around guide or guides. In this type, the tension is multiplicated
washers. Spare washers can be kept in the spindle itself. Whenever required, the washers can be placed on
and hence the name is given. This principle is widely used in Gate type of tensioner. In this method two
the top disc. Yarn is passed in between top and bottom discs. Due to friction, tension is applied on the
types of tensioner are there
yarn. According to the yarn count, washers are charged. Different coloured washers are used for different
Gate type and compensating type
counts.
Gate type:

d) Disc and spring type

A – Fixed comb

A – Disc B – Movable comb

B - Spring C – Yarn

C - Knob D – Pulley

D - Yarn E – String

F - Weight

This type consists of two vertical combs. One comb is fixed (or) stationary while the other is movable. The
movable comb is connected to a weight arrangement. So this comb can be turned in and out around its
axis. Yarn is passed in between these two combs, alternately to the right and left. If the movable comb is
deflected more from the fixed comb, by the weight arrangement, it results in greater deflection in the yarn.
Hence more tension is applied on the yarn. Similarly less weight, leads to less tension on the yarn. Type of Drums: Generally in drum winding process grooved drums are used. In this grooved drum a
Compensating type: continuous helical grooves are interconnected in clock wise and anticlock wise direction. In drum winding,
This is the development in the Gate type of tensioner. In this type, a magnetic device controls the the surface speed of the drum is same throughout the process. If cheese is wound on the drum winding
deflection of the movable comb according to the tension variations and hence the winding tension is there is no problem in winding because of its having even smooth surface and also cheese is having same
maintained uniform. This method is used in modern automatic cone winding machines. speed as drum speed. But in case of cone winding on drum winding machine, the surface speed is varies
based on its circumference of the cone, problem arises in winding uniform package. In winding the cone,
Merits of multiplicative type of tensioners: base portion requires more length of yarn than the nose portion. This is achieved by using different type of
1. It will not affect the twist in the yarn drum. There are two different types of drums, 1. Half accelerated drum 2. Fully accelerated drum
2. Tension is applied gradually in the yarn
In half accelerated drum, the surface speed and traversing speed is constant throughout the
3. Some degree of self compensation in the tension is achieved
winding process. Length of yarn wound on the cone is same in both base and nose portion.
Demerits of multiplicative type of tensioners:
In fully accelerated drum, the traversing speed is varied by changing the angle of groove present in the
1. Incoming tension variations are multiplied
drum. So that the length of the yarn wound on the base portion is increased by decreasing the angle of
2. Threading is difficult
groove and length will be less in nose portion by increasing the angle of groove as shown in figure.
1.3.5 SPLICING:
This is a new technology for piecing up the broken ends. This is used in Schlafhorst Autoconers. A
Knots and Splicers In winding to get a continuous length of yarn, the yarn from sinning cops are
separate attachment is necessary for splicing the yarn.
combined. So it is necessary to piece two ends. Piecing is carried out by putting a knot. If manually a knot
Methods of Splicing:
is put, then the knot will be bigger and it will be serious in weaving. The knot may not go through the
There are two methods of splicing.
heald wires and reed wires in loom. Also in knitting thick knot will not pass through the needles. To avoid
1. Wet splicing 2. Air splicing
this, mechanical knitters are provided. These knitters are used to get a) Dog Knot b) Weaver‟s knot c)
1. Wet Splicing: This is carried out manually by the winders. Each winder is provided with a small
Fisherman‟s knot. For cotton yarn weaver‟s knot is adequate. For synthetic blends the weaver‟s knot mayslip
trough containing water, hanging from the winder neck by a small cord. In this method, the two broken
and hence the fisherman‟s knot is preferred. The best knot is that which gives least slippage and end
ends are overlapped and then water is applied to join them. In some machines this is done automatically
breakage under working condition.
by water jet principle. But this method is not much used.
2. Air Splicing: In this method, air is used to piece the two broken ends. There are two stages in this
splicing. In the first stage, the two broken ends are passed through suction holes provided in the splicing
unit and are untwisted by passing compressed air to open the fibers at the broken ends. Now in the second
stage, the two broken ends are overlapped in an inclined slot which is provided in an intermingling
chamber. After overlapping, a jet of compressed air is passed vertically and tangentially through the
intermingling chamber by which the joining of broken ends is achieved.
Advantages of Splicing:
1. Even yarn is produced
2. No tail end as in weaver’s knot and Fisherman’s knot. So shearers are not necessary
3. Yarn will easily pass through heald and reed wires. So weaving performance is improved.
4. In knitting needle breakages will be very less.
5. Fabrics produced by using the spliced yarns, will be superior in quality.
The knots are shown in figures. These are done manually also. But the tail ends will be longer.
So the knitters are used by workers in high speed winding machine. In automatic winding machine there is
knotter head which his used to suck ends from supply and delivery packages and knotting is done. Extra
tail ends are sheared by shearers. So there is less chances of big knots and yarn will be superior in quality.
Knotting is also carried out when an end breakage occurs. In high speed winding, a
broken thread stop motion wire works and the cone is lifted from the surface of the from. The
worker comes to the drum unit and takes end from cone then from cop. Then he puts the knot by
using the mechanical knotter. In automatic winding machines the knotter consists of two clamps.
One clamp sucks end from cone and another one sucks the end from cop and knotting is done
mechanically.
In automatic winders for putting weaver‟s knot and Fisherman‟s knot separate attachments
are necessary. For synthetic blends the Fisherman‟s knot is preferred than weaver‟s knot.