The document discusses recent advancements in ring spinning technology, focusing on improvements to yarn quality, production monitoring, and the introduction of condensed spinning systems to eliminate the spinning triangle and enhance yarn structure. Key developments include new cradle designs, active cradles, and various compact spinning methods that aim to reduce imperfections and improve yarn strength. Additionally, the document details innovations in drive systems that allow for precise adjustments in yarn count and twist without mechanical intervention.

1. RECENT DEVELOPMENTS IN
RING SPINNING

2.  The quality of a yarn is judged by many
parameters, like evenness, count CV%, strength,
imperfections, yarn appearance, etc.
 Thus, in short staple spinning system, to produce
yarn of acceptable quality, the raw material has
to be processed through a sequence of machine.

3. CATEGORIES OF DEVELOPMENTS
 The developments or innovations can be divided
in different categories:
1. Minor modifications.
2. Modification related to quality/production
monitoring or enhancement in production/speed.
3. Major modifications.

5. LIMITATIONS OF RING SPINNING

6. DEVELOPMENTS IN CREEL
Suspended Creels:

7.  The bobbin creel is simple in design, but it can
nevertheless have an influence on the occurrence
of faults.
 If take-off from the bobbin is not trouble-free,
incorrect drafts or even thread breaks occur.
 This is why bobbin suspension pivots are used
nowadays rather than bobbin holders.
 Nowadays bobbin creels occupy lots space in terms
of width, as very large roving bobbins are usually
used.

8. ROVING GUIDE DRIVE
Zinser OptiMove:

9. Marzoli twin traverse method:
 A double traverse motion for the roving guide used by
Marzoli covers the wider area over the cots and
consequently increases the cots and apron life.

10. SECTION THROUGH THE DRAFTING SYSTEM

11. THE INA DRAFTING SYSTEM

17. MODIFICATION IN DRAFTING
ARRANGEMENT
Ri-Q bridge and Arco Bridge:
 Conventional bridge-shaped cradles are flat
with a step guide.
 New bridge cradles are designed with a convex
shape (arc).
 Rieter’s Ri-Q bridge and Marzoli’s Arco bridge
are arc-type cradles.

19.  With the new design, the top and bottom aprons
assume concave and convex shapes
respectively in the working region and are kept at
a higher tension compared to that when running
on flat cradles.
 This type of arrangement extends the pressure
fields on the fibres held by the middle rollers
close to the front rollers, improving the guidance
of short fibres.

20.  When spinning finer yarns, fewer fibres are
drafted and arc-shaped cradles might be
useful.
 Arco bridge cradles are recommended for
compact and finer yarns.
 It has been shown that Rieter’s bridge
reduces yarn CV% and imperfections and
improves yarn strength by 18%.

21. Suessen ACP cradle:
 Suessen Active Cradle with special Pinspacer (ACP) is
able to improve the yarn quality.
 The sector length of 15-30 mm, in the drafting system,
where the inter-fibre friction is minimum, do not able to
guide short fibres.
 The pinspacer of ACP deflects the fibre in this zone
thereby increases the friction field of the front roller
nipping line towards the cradle.
 The tendency of the fibre spread is suppressed along
with improvement in fibre orientation and extension
consequently improves overall regularity and strength of
the yarn.

23. Technological advantages of the Active Cradle
over a conventional rigid cradle
 Lower cradle spacers for perfect operating
stability
 Less imperfections
 Less variations in yarn strength and elongation
 Better tenacity
 Less yarn irregularity (USTER CV)

24. Saddle spring loading:
 The top rollers are also loaded directly by plate
springs as shown in figure.
 The force of the springs is carried over to the top
rollers without the use of any moving part and
therefore involves no friction.
 The pre-tension of the spring can be changed by
a cam at the front weighting unit to adjust the
load.

26.  The critical feature is that the top rollers are loaded
directly by heavy-duty plate springs without clearance or
friction.
 Furthermore, the plate spring is supported free from play
in the top arm body.
 At the same time, the plate spring serves as a guiding
element and prevents the possibility of lateral forces from
acting on the top roller position.
 In addition, the mechanical treatment of the wider top
roller supports will guarantee the precise parallelism of
the top and bottom roller axles.

27. Delayed start-up of drafting rollers:
 The drive for the drafting rollers is a rigid one (by gears)
and the spindle is driven by a flexible drive (belt).
 The initial belt tensions on both sides of the spindle are
the same while the machine is at rest.
 When the ring spinning machine is started, the belt
tension in the forward direction increases, and at the
back it decreases enough to build up the required torque
on the spindle.

28.  Additional slackness present on the spindle belt
compounds the problem.
 The acceleration of the spindle lags behind that of the
drafting rollers and the yarn slackens; if it slackens much,
this might lead to balloon instability and the end breaks.
 Delaying the starting of the drafting rollers by a few
seconds would solve this problem.
 In the Marzoli ring spinning machine, at the beginning of
cop build-up, the starting of the drafting rollers is delayed
so that the spindle starts to rotate first, which tightens the
initial yarn ends.

29. CONDENSED SPINNING SYSTEM
 All the optimizations and improvements of the
ring spinning frame have not enabled the
reduction of the spinning triangle, which can be
defined as the most problematic and weakest
spot in the yarn formation process using the
ring-traveller system.

30.  The spinning triangle that occurs while the yarn is formed
is the cause of many fibres leaving the drafted roving, or
being partly spun into the yarn with one end only.
 This causes greater waste of fibres, lower exploitation of
fibre tenacity in yarn, poorer appearance and greater
hairiness of the spun yarn.
 The newest research in the field of ring spinning has
minimized spinning triangle, or even without it at all. This
modified process is called compact or condensed
spinning.

31. CONVENTIONAL VS COMPACT SPINNING

32.  If the twists are imparted, the fibres at the edges are
either loosely bound or lost as a fly and produce
hairy yarn.
 The main purpose of the compact spinning is to
eliminate spinning triangle at front roller, technically
speaking the ‘weakest point’ of the ring spinning.
 The elimination of the spinning triangle results in
permanent change of yarn structure, which
distinguishes the compact spinning from
conventional ring spinning.

33. METHODS OF COMPACTING FIBRE STRAND
Aerodynamically compacting system:
a) Suction by drum and
b) Suction through perforated apron.
Mechanical compact system.
Magnetic compacting system.

34. AERODYNAMICALLY COMPACTING SYSTEM
Com4Spin® of Rieter:

35. •THIS COMPACTING PROCESS IS SUPPORTED BY A SPECIALLY
DESIGNED AND PATENTED AIR GUIDE ELEMENT (6). THE
SPECIAL FEATURE OF "AIR GUIDE ELEMENT" IS TO ENHANCE
THE COMPACTING EFFICIENCY IN THE COMPACTING ZONE

36. SUESSEN ELITE® COMPACT SPINNING

38.  The profile tube (S) has a small slot in the area (S1-S4)
and is closely embraced by a lattice apron.
 The porosity of the apron and the negative pressure in
the slot area result in a condensed fibre bundle that is
transported up to the zone (4-S4).
 The oriented fibres remain completely condensed and
closed up to the delivery clamping and twist insertion line
(4-S4) because of the slot length.
 Therefore, no spinning triangle is formed, which enables
literally all the fibres to be wound into the yarn and
optimal yarn structure.

39. ZINSER AIR-COM TEX 700

41. COM4®WOOL BY COGNETEX
 Com4®wool is the trademark of the compact spinning for
long staple fibres that Cognetex (an Italian based
company) has developed for 'IDEA' make ring spinning
machine in cooperation with Rieter.
 Here front drafting roller is replaced by a perforated
drum. This enables the airflow to compact the fibres
directly on the drafting cylinder.
 It is claimed by the manufacturer that for the wool sector,
a patented elastic control roller with a slant axis prevents
fibres that are being pinched at the same time by the
drafting system and the front roller, from being tensioned.

42. OLFIL SYSTEM BY MARZOLI
 Olfil is the compact spinning system designed
and developed by Marzoli.
 The condensing system is positioned at the
delivery of the drafting unit.
 The bottom section of the condensing system
has one stainless steel pipe for every 8
spindles with a perforated apron at each
spindle.

43.  The top section of the condensing system is
composed of two pressure rollers driven by the
toothed belt.
 For each 48 spindles section, there is one
motorized inverter driven fan that provides
suction for the condensing system.
 A wide area air distribution and compensation
allows for the correct balancing of the suction.

44. TOYOTA'S COMPACTING METHOD
 RX240NEW-EST-make Toyota's ring spinning
frame is equipped with compact spinning system.
The condensing device consists of suction slit and
perforated apron and works on aerodynamic
compacting principle.

45. The special features of the machine, as claimed by
the manufacturer are:
1. Smooth collection of fleece fibres by suction slit
and perforated apron.
2. Precise slip-free rotation of the perforated apron
because of positive drive of the top and bottom
delivery rollers.
3. Inverter-controlled adjustable suction pressure.
4. Easily detachable condensing unit.

46. 5. Perforated apron, driven by a bottom roller,
is not affected by top roller diameter.
6. For easier handling, each 4-spindle
condensing unit can be conveniently
detached and disassembled without using
special tools.
7. The rollers are driven by a geared front-
bottom roller and maintenance-free carrier
gear, resulting in a simpler structure.

47. MECHANICAL COMPACT SYSTEM
 Mechanical Compacting Spinning (MCS) is given by
Officine Gaudino for long staple.
 This compact system makes the compact yarn
without the use of air.
 The compacting of the fibre strand is carried out with
smooth bottom front roller and an angled top roller.
 Officine Gaudino offers long staple spinning machine
(Model FP 03) with mechanical compacting system.

48.  This compacting system does not require the additional
suction system.
 The MCS consists of an additional smooth bottom front
roller and an angled top roller.
 These rollers run at a slightly slower speed than the front
drafting rollers and this 'negative draft', coupled with
offset top roller, creates false twist which compacts the
drafting strand as it comes out from the compacting zone.
 This system can be incorporated into the new machines
and is claimed to be easily added or taken off the
spinning frame.

49. MAGNETIC COMPACTING SYSTEM
 Magnetic Compact Spinning, as the name implies, is a
compacting system that makes the compact yarn with the
use of magnetic compactor.
 The RoCoS compact spinning system, developed by
Hans Stahlecker of Rotorcraft Maschinenfabrik,
Switzerland is incorporated into LMW's Ring Spinning
Frame.
 RoCoS stands for 'RotorCraft Compact Spinning' system
and it works without air suction and uses magnetic
mechanical principle only

51.  The bottom rollers (1), support the front roller (2) and
delivery roller (3). The condensing zone extends from
clamping line A to B.
 The very precise magnetic compactor (4) is pressed by
permanent magnets without clearance against cylinder
(1).
 It forms, together with the bottom roller, an overall
enclosed compression chamber whose bottom contour,
the generated roller surface of the cylinder, moves
synchronously with the strand of fibres and transports
this safely through the compactor.

52. ADVANTAGES OF CONDENSED YARN
SPINNING
 Considerably reduced yarn hairiness
 Highly increased yarn strength and breaking
extension
 Sizing and Singeing can be completely or partially
dispensed with.
 Conventional two-fold yarns can be replaces with
compact spun yarns.
 Classical combed yarns can be partly replaced by
EliTe compact spun yarns
 Consistently reduced fly generation/liberation, i.e
better fibre utilization and cleaner spinning
conditions.

53.  Noil percentage at the comber can be reduced, because
short fibres, in particular, are better integrated in the yarn
during spinning
 Significantly reduced imperfections, resulting in better
yarn quality.
 Appreciably reduced ends-down, leading to higher
machine efficiency.
 Softer fabric handle
 Increased pilling resistance, luster and fabric strength
and
 Higher yarn sales price due to better yarn quality.

54. DISADVANTAGES OF CONDENSED YARN
SPINNING
 The various methods of condensed yarn spinning
described here no doubt promise ideal yarn
characteristics, but their commercial popularity is still
under test due to:
1. Higher capital cost of the machinery
2. Increased maintenance of suction / perforated devices
3. Fibre loss due to suction into the perforated drum in
Rieter’s Comfor process and chocking of suction holes
in the perforated apron in Suessen’s EliTe proess.

55. SIRO SPINNING

56. SOLO SPINNING

58. DEVELOPMENTS IN RING & TRAVELLER
 The ring is the race track over which the traveller has
to revolve to impart twist to the yarn balloon.
 Running at a speed of 110-170 km/hr, the traveller
generates heat at its interface with the inner edge of
the ring.
 As the traveller is very light, its temperature can
reach as high as 3000C in spite of heat losses due to
conduction and convection, leading to localized
melting and it quickly wearing out.

59.  Considerable research work has been done by
the ring and traveller manufacturers, aimed at
reducing the frictional wear resistance of the ring
and travellers and increasing heat conduction at
the traveller-ring interface.
 This has resulted in the use of carbon-rich steel,
lubricated rings, ceramic rings, special finishes
(diffusion treatment, nickel plating) and new
designs of ring and traveller combinations with
an increased area of contact.

60.  The travellers used for short staple spinning are C-
Type on a low crown ring/ T-Ring, Orbit and SU.

61.  The area of contact between the ring and traveller is
greater in the case of SU and Orbit types, providing
better heat dissipation.
 The traveller describes an up-and –down motion and
tilts in the radial and tangential planes continuously
due to the variation in the balloon size and its
tension and also the change in the lead angle with
the ring rail movement.
 In SU and Orbit rings, the design of the ring itself
provides a certain balancing effect on the traveller
while it is tilting / oscillating.

62. TRAVELLER WIRE-PROFILE

63.  The fibres protruding from the yarn body are crushed
between the ring and traveller and form a steady
lubricating film.
 The fibre lubrication prevents metal-to-metal contact and
reduces the friction coefficient considerably, in cases
from 0.12 to 0.08, depending on the fibre.
 With new rings, metal-to-metal contact occurs at the ring-
traveller interface and gives rise to a high friction
coefficient that results in increased yarn tension and
breaks.
 When rings are changed for new ones, it is usual practice
to run the spindle at lower speeds then progressively
increase the speed over a period of a few days, called
‘running-in’, to generate fibre lubricants and deposit them
on the ring.

64. DEVELOPMENTS IN DRIVE SYSTEM
 A unique trend has been observed for
changing the yarn count and twist by
pushing a button, i.e. without any
mechanical intervention.
 Another trend is the division of drafting
systems on long ring spinning machines into
two halves, each driven independently.

65. Rieter FLEXIdraft:
 The FLEXIdraft flexible drive, equipped on Rieter
G33 ring spinning machine, features separate
drives for the drafting system and the spindles.
 Synchronous motors controlled by frequency
converters drive the drafting system cylinders
individually.
 The cylinders are split in the center of the
machine to ensure very smooth running and
drafting operation.

66.  The multi-motor drafting system drive (2 motors
on each side at the head and foot of the
machine, i.e. a total of 8* motors) offers
maximum user friendliness when adjusting the
spinning parameters to new conditions.
 This system enables change in the yarn count,
twist and twist direction (S/Z) via, the control
panel of the machine. The drafting rollers are
split in the centre of the machine to ensure
smooth running of drafting operation.

68. Advantages
 yarn count and twist change at the push of a
button
 high-precision settings
 considerably fewer ends down at start-up
 no mechanical work
 significantly reduced noise levels
 start-up and spin-out in quarters
 maintenance-free
 S/Z twist can be set at the control panel

69. FLEXIStart:
 On the basis of FLEXIdraft, each drafting system
drive can be started or stopped individually via,
FLEXIstart system. Thus depending on machine
length, 1-sided or 2-sided drafting system drives are
used.

70. ZINSER SYNCHRODRIVE, SYNCRODRAFT AND
SERVODRAFT
 Zinser SyncroDrive is a multi-motor tangential belt drive
system.
 The system employed several motors arranged at
defined positions to drive spindles through tangential belt.
 The consistency in spindles speed relative to each other
minimizes the twist variation apart from reduction in noise
level and minimum power requirement.

72.  SynchroDraft transmission is for long machines to
drive the middle bottom rollers from both ends,
consequently minimizes twist variation between gear
end and off end of the machine.
 Zinser ServoDraft system employs individual motors
for driving bottom rollers of the drafting system.
 Hence yarn count and twist change can be done by
simply feeding required parameters at the control
panel of the machine that adjust the motors speed
accordingly.

73. TOYOTA ELECTRODRAFT SYSTEM
 The Toyota ElectroDraft System features
independent servo motors drive for front
and back rollers.
 The spindles are also driven by separate
tangential drive system where one motor
drives 96 spindles.
 Thus the required draft and yarn twist can
be set via, control panel.

74. MARZOLI MULTI-MOTOR DRIVE SYSTEM
 The main motor with a relative inverter drives
only the spindles.
 An asynchronous motor drives the ring rail. The
drafting rollers have two separate drives, one on
each side of the spinning machine, through
asynchronous motors.
 On each side, one motor drives the front drafting
rollers and the other one drives the middle and
back drafting rollers.

75.  The production parameters, namely main draft, twist and
shape of the bobbin, must be entered at the control
panel, making any gear changing redundant; this ensures
fast and precise control of important parameters, thereby
increasing the flexibility of the ring spinning machine.

76. SPINDLE DRIVES
Two types of system are employed t drive
the spindles, namely 4-spindle group drive
with tapes and tangential belt drive.

77. TANGENTIAL SPINDLE DRIVE

78.  In the tangential belt drive, a belt extends from the motor
past the inner side of each spindle.
 A number of tension rollers are placed along the belt to
press against it and ensure a constant tension on the belt
for all the spindles.
 However, there is a possibility of non-uniform tension on
the belt due to variations at the locations of the tension
rollers. This might lead to a variation in yarn twist on each
spindle.
 Tangential belt drives are available in three forms: single,
double and grouped. If a belt breaks, production is
affected on a large number of spindles.

79. 4-SPINDLE TAPE DRIVE

80.  In this arrangement, a jockey pulley mounted on
the main shaft of the spinning machine drives
two spindles on one side of the machine and a
further two spindles on the other side of the
machine by means of a flexible tape.
 Two tension rollers on either side of the pulley
ensure an even, firm tension on the belt.
 The 4-spindle drive offers a greater angle of
wrap around the spindle wharves by
manipulating the position of the tension pulleys.

81.  This ensures less slippage on the belt, and
provides constant rotation speeds to the spindles
over the total length of the machine, regardless
of the number of spindles on the machine.
 Furthermore, it leads to less tension on the belt
and hence a lower consumption.
 In the event of a belt breaking, only the 4
spindles are affected, and it is also a quick job to
replace.

82. Zinser OptiStep and Optistart:

83.  OptiStep is a system of adjusting spindle speed in 10
different ranges through-out the cop builds on Zinser ring
spinning machines.
 The start-up, tip and main spinning speeds can be
defined with a 10 point speed curve.
 Similarly OptiStart is a running-in programme for ring
travelers to perform the running-in phases of the ring
travellers with precise accuracy up to production speed.
 Hence the traveller service life is substantially extended.

84. Marzoli variable spinning speed:

85.  Marzoli’s variable spinning speed ensures high
productivity and reduced breakages during bobbin
build up.
 The speed increases as yarn tension decreases, in
order to maintain high quality minimizing
irregularities.
 The software program also balances energy supply
with spinning speed.
 In case of power fault the computerized system is
able to control the stop of the machine without yarn
breakages.

86. ZERO UNDER-WINDING CONCEPT SERVO
GRIP FROM RIETER
 The yarn has to wind several times around the lower
end of the spindle to hold it in the spinning position
at the time of doffing.
 These under-windings often cause multiples end
down and lead to fibre fly when machine is restarted
after doffing.
 SERVOGRIP is a system of doffing ring cop without
the under-winding threads. The main elements of the
SERVOgrip is a patented clamping crown.

89.  At the time of doffing the ring rail moved
downward and the clamping crown gets open
while the spindle is still revolving slowly.
 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; enabling piecing after machine is
started.

90. MARZOLI WONDERCLEANER

91.  The Marzoli rather uses a wonder cleaner to remove the
underwind.
 Wondercleaner is an overhead cleaner with suction unit.
 This removes underwind only when the ring rail has reached
certain minimum height.
 To cut the under coil binding on the spindle, it is used a simple
metallic cutter which cut the yarn when the blower pushes it
against the spindle.
 The yarn is reduced in small pieces and then scattered on the
floor. This solution is good enough for medium and fine yarn.

92.  The Wondercleaner is an overhead cleaner with
a positive suction unit which perfectly removes
the winding of the binding coils for coarse yarn.

93.  The spindle cleaner is used with the blower only
between doffing cycles, when the ring rail has
reached a minimum height.
 It cuts and collect the underwind yarn coils from
every spindle instead of just cut and scatter them
in the room.
 After the cleaning is performed, the suction
activity remains idle (Wondercleaner works as a
conventional overhead cleaner).

94. MARZOLI DIFFERENT WINDING GEOMETRY

95.  The production of high quality yarn is strictly
related with the geometry of spinning.
 Marzoli offers three geometries (180-200 mm,
210-230 mm, 240-260 mm) which keep the
spinning angle variation inside the best theoretic
range.
 The ideal distance between anti-balloon, delivery
angle (front roller), guide thread and ring rail has
been optimized.

96. REDUCTION OF HEAT IN SPINNING ROOM
Rieter INTERcool:

97.  INTERcool is a closed-circuit, in the machine integrated
cooling system.
 INTERcool feeds the heat from all the motors and
frequency converters directly to the air conditioning
system via an internal heat exchanger. This considerably
reduces the load on the air conditioning system.
 The integrated system prevents the heat from the
machines from being released into the spinning mill.
 The air sucked in via the extraction system flows through
the heat exchanger and feeds the heated air directly to
the exhaust air duct of the air conditioning system.

98. Advantages:
 closed-circuit cooling system efficiently reduces
the load on the air conditioning system
 constant spinning climate along the entire length
of the machine
 positive influence on running properties and yarn
quality
 no fly formation
 no filter
 no filter cleaning necessary

99. Marzoli:

100.  The drives have been installed in an electric box
with forced ventilation in order to allow a proper
operation.
 The pneumafil suction air is discharged
separately into a centralized fibre compactor, and
the main motor releases hot air into the
underground duct which transports the air to the
air conditioning system.

101. AUTOMATION IN RING-SPINNING
MACHINE
Automation in ring spinning consists of
 Transferring the roving bobbin into creel of
the ring spinning machine
 Stopping the roving feed when it breaks
 Machine and production monitoring
 Doffing
 Transporting cops to the winder

102. 1. Roving bobbin transfer:
 On the creel of the ring spinning machine, optical
sensors are placed near each of the roving
bobbins.
 Full roving bobbins move in the area near the
ring spinning machine.
 If a bobbin is exhausted, the movement of roving
bobbins is stopped and a T-shaped lever with
pegs at each end for holding the roving bobbin
comes into action.

103.  One side of that takes the new bobbin and the
other end takes the empty roving bobbin from
the ring spinning machine creel.
 The lever then rotates through to 1800 and
transfers the fully wound bobbin to the ring
spinning machine’s creel and the empty bobbin
to a creel nearby.
 The operator only joins the roving ends, which
saves them time and reduce roving bobbin run
out time caused by their negligence.

105. 2. Transfer of roving bobbin from roving machine to
creel of the ring frame machine
 Most machine manufacturers offer the automatic
transport of roving bobbins to the creel of the ring frame
machine.
 A design offered by Oerlikon schlafhrost on the Zinser
351 ring spinning machine has four rows of creels, which
are designed as transports rails driven by trolley trains.
 Three rows of creels are in working positions and the
fourth one serves as a reserve. If one of the rows of
working creels runs out of roving bobbins, the next one
automatically takes over as the supply creel.
 The operator of the ring-spinning machine to join up
roving ends to the waiting full bobbins.

107.  By simply pressing a button on the ring-spinning
machine, the trolley with empty tubes is sent back
and a new full trolley train requested.
 The empty trolley train now enters the cleaning
station then waits in the storage section to be filled
again.
 The control centre sends a new full trolley train to the
ring-spinning machine.
 There are two modules offered: a stand- alone
module integrated into the transport system or a tube
cleaner integrated into the roving machine.

108. How bobbin transport to the ring frame?
 CIM TRACK3 – Fix flow
 CIM TRACK4 – Flex Flow
The word CIM means Computer Integrated
Manufacturing. Apart from optimal yarn quality, high
productivity, reliability and flexibility are demanded of
modern ring spinning systems.
 For these requirements, offers ring spinning systems with
modular design with roving frames, ring spinning
machines and the optimal connection of these by roving
bobbin transport systems for any material flow
requirement.

109. Creel Automation CIM Track 3: Fix Flow
Principle
 With the so-called AutoFlow systems, the roving
bobbin transport systems, it provides automation
for roving bobbin transportation to the ring frame.
 FixFlow is a fixed linkage, i.e. a circular conveyor
system, which is ideally used in spinning mills
with a constant production and spinning
programme.

110. •With CimTrack 3, there are 3 TRACK of roving bobbins
are directly transported into the ring spinning machine
creel using trolley trains (one per creel row).

111.  Bobbin exchange is dropped. The operator has
only to piece up the roving. A row change is
performed.
 The creel rows are initially fed with bobbins that
have stepped fill levels.
 There is also a changing spare row on each
machine side.
 Following this, the resulting change cycle means
that full roving bobbins are transported in
whichever creel row becomes vacant.

112. Automation CIM track 4:
 It is based on the principle of FlexFlow. Flex Flow
is a flexible linkage.
 That means the material flow system is ideally
used in spinning mills With frequently changing
production and spinning programmes.
 As a specialist for roving frames and ring
spinning machines, is capable of offering – apart
from standardized solutions – the suitable
individual transport system for any material flow
requirement.

113.  With CIM Track 4, there are 4 track of roving
bobbins are directly transported into the ring
spinning machine creel using trolley trains (one per
creel row).

114.  Bobbin exchange is dropped. The operator has
only to piece up the roving. A row change is
performed.
 The creel rows are initially fed with bobbins that
have stepped fill levels.
 There is also a changing spare row on each
machine side.
 Following this, the resulting change cycle means
that full roving bobbins are transported in
whichever creel row becomes vacant.

115. 3. Roving Stop Motion:
 When a yarn breaks during spinning, the drafting
rollers continue to process the fibre strand, and
fibres are sucked into an aspirator and go as waste.
 In poor spinning conditions (high relative humidity)
the drafted fibres lick on to the drafting rollers and
form a lap.
 This can damage the top rollers and aprons and
causes ends down on the neighbouring spindles.
The removal of roller lap also causes additional
problems.

116.  All the costs (labour, power and indirect costs) incurred in
converting the fibres into the roving become
unproductive.
 It would be desirable to have a roving stop motion that
interrupts the flow of fibres from the time an end breaks
until joining is carried out.
 Roving stop motions can be provided as part of the
travelling device or as assemblies at each individual
position.
 The former is more economical but the roving stop would
not be immediate as it in the case of integrated
equipment.

117.  Marzoli has brought out a roving stop motion in
which the roving is locked at the back of the drafting
system as soon as a yarn break is detected by a
sensor.
 The sensor, which is placed below the lappet,
senses the presence of yarn at each spindle
position.
 Additionally, the sensors at each position are used
as data collections units for the status of each
spinning position.
 This has potential applications for machine
monitoring and production data acquisition.

118. 4. Monitoring systems:
 Ring-spinning monitoring system are available for
obtaining data about individual machines, individual
blends or the complete ring-spinning installation from
printed reports or from screen displays, including:
spindle rpm, mean yarn twist, production
data(machine and spindle), machine efficiency and
downtime, doff time, number of doffs, ends down and
mean period for each end down.
 Many sensors are used to monitor different of the
machine to acquire different data.

119.  A travelling sensor based on the principle of
magnetic induction moves continually back and forth
at about ring rail level on each side of the ring-
spinning machine.
 If a yarn breaks, the sensor emits a pulse indicating
an end down, while simultaneously identifying the
spindle by its code number.
 This sensor registers the yarn break at one spindle
several times before the positions is returned to
production. The time that an end remains down is
computed.

120.  Another sensor, fitted to a roller corresponding to
the front roller, detects delivery machine and
machine downtime; a further sensor detects the
number of doffs and the time taken for each doff.
 All this information is passed on to a computer
for displaying, printing and evaluating over a
given period.

121. Rieter Individual Spindle Monitoring (ISM)
 Individual Spindle Monitoring (ISM) is a quality monitoring
system. ISM is based on optical scanning of the traveler.
 If the traveler is no longer rotating on the ring, the control
system detects an end down and indicates this by
illuminating the spindle LED directly at the spinning
position.
 Since the traveler speed is continuously monitored,
slipper spindles (spindles running at less than their rated
speed for a defined period of time) can also be precisely
identified and indicated.

123. 1st level: machine
 Two signal lamps on the headstock and tailstock of the
ring spinning machine indicate the side of the machine on
which the ends down threshold has been exceeded.
2nd level: section
 A high-intensity LED (Light Emitting Diode) on each
section (24 spindles) indicates that an end down or a
slipper spindle has been detected in this section.
3rd level: spindle
 This level indicates which spindle is operating outside the
defined tolerances. Here the malfunction can be
identified precisely on the basis of the light signal shown
by the spindle

124.  ISM – the Rieter individual spindle sensor – helps to
optimize the speed curve on the ring spinning machine
and displays the influence exerted by various factors,
such as raw material blend, on the number of ends down.
 Distance covered by the operator during will be reduced
by about 40% with the installation of ISM as shown in
figure.

125. Advantages of the 3-level light guidance
system:
• Easily detect ends down
• Immediately identify slipper spindles
• Deal with problems selectively through personnel
guidance
• Optimize operations by reducing routine tours of
inspection

126. Zinser GUARD system:

127.  The individual yarn monitor FilaGuard monitors the
rotation of the steel ring travellers on each spindle
and detects any yarn break immediately.
 Optical signals indicate the specific yarn break,
directing the operating personnel to the spindle of
yarn break to rectify the problem.
 The automatic roving stop RovingGuard, which
responses within milliseconds, interrupts the roving
feed in case of yarn break thereby prevents material
loss and minimize lapping tendency.

128. 5. Centralized Control of Spinning Parameters and
Retrievable
 Rieter’s MEMO set product stores spinning parameters
for up to 18 different yarns.
 The data are available at all times and can be retrieved
and processed. The parameters are downloading directly
from a laptop, and transferred between several spinning
machines.
 Machine functions, spindle drive, drafting arrangements,
auto drafting, and traveller cleaner’s details are all
centrally controlled and always available on the display
unit.

129.  Real-time information is made available
regarding output and machine status.
Adjustments to production parameters, e.g. for
yarn twist, are possible via a keyboard.
 When changing the blend, modifications to
machine data can be made quickly.
 The time remaining to the next doffing process is
available on a display, which can facilitate the
allocation of personnel.

130. 6. Automatic Doffing:
 There are two types of automatic doffing for ring-spinning
machines: stationary and travelling devices; the former is
mostly used in new machines.
 After completion of doff, the doffer, which contains empty
ring bobbins and also the provision for holding the fully
wound bobbins, rises from below.
 Fully wound cops are then gripped by the doffer and
transferred to it, and then empty bobbins are transferred
from the doffer to the spindle of the ring-spinning
machine.
 Subsequently the doffer comes back to its original
position and transfers all the full cops to a conveyor belt,
which might be used to transfer them to the winding
machine.

131. Auto Doffing Cycle in Ring Frame: (Model Rieter G35)

134. Auto Doffing Cycle in Ring Frame: (Model
Marzoli MPN)
 The automatic doffing has an intermediate
parking rail for the empty tubes.
 The bottom conveyor holds only full bobbins and
therefore their size (diameter) could reach bigger
diameter without the limitation created by the
presence of another empty tube.
 The doffing cycle is very reliable and simple. The
individual peg is always aligned with the spindle
thanks to a mechanical lever which aligns 24
pegs at a time.

135.  A pneumatic piston moves the pegs without the need
of any metallic band or chain which can eventually
over-stretch creating misalignment with the spindles.

138. 7. Automatic cop transport to winding:
 Automatic cop transport to winding can be
classified into:
a) intermediate transport between spinning and
winding sections/departments and
b) direct link to a specific winding machine.

139.  Intermediate cop transport

140.  In an intermediate transport system, the transport
devices take up the boxes of full cops coded according to
their contents, and deliver them to a distribution station.
 This station directs the boxes to the cop preparing unit of
the corresponding winding machine.
 The empty tubes are deposited in other boxes and
returned via a second conveyor system to the ring-
spinning room.
 Intermediate transport systems are very flexible, rapidly
adaptable and less dependent on the layout of the
building that houses them. However, they can be rather
complex, costly and liable to faults.

141.  Direct link system

142.  With the direct link system, the ring-spinning
machine and the winding machine can be
coupled to form a production unit.
 The cops doffed at the ring spinning machine are
passed to the winding machine.
 The transfer speed must correspond to the
production rate of the winding machine; hence it
is slow.

143.  Empty bobbins are returned to the loading
station of the auto doffer at the ring spinning
machine.
 The number of winding units chosen should be
such that the cops delivered after one doff have
just been rewound when the cops from the next
doff become available.
 The requirement for synchronizing each machine
is difficult to achieve when products are changed
frequently.

144. FANCY YARN AND CORE SPUN YARN SPINNING
Technologies to produce core yarns
 For processing both elastic and hard filaments,
attachments to feed the filaments into the front roller nip
are available that can be retrofitted on existing ring
spinning machines.
 In the case of manufacturing elastic filament core spun
yarn, the control of stretch or pre draft on the filaments
has to be carried out precisely using positively driven
rollers that support the filament package.

145.  Selection of the appropriate roughness and finish for the
rollers surface is critical to avoid stick-slip of filaments.
 Servo motors are also used to drive guide rollers. For
processing hard core filaments, a special creel for
supporting and unwinding filament cop is installed.
 With very fine yarn, precise centering of the filament in
the resultant composite yarn is difficult.
 A floating filament guide system with an intermediate
roving guide bar is used to ensure the relative positions
of filament and roving.

147.  One of the main defects of core spinning is the
production of yarn without any filaments when the
filaments break. Different systems are available to
avoid this.
 Mobile filament detectors can be used, one on each
side of the machine.
 An individual filament detector, together with a roving
stop mechanism, would be ideal and could be
adapted to stop the production of a particular spindle
when the filament broke.

148. Rieter VARIOspin for fancy yarns:
 Rieter VARIOspin (optional) is a fancy yarn
production system incorporated on ring frame (Rieter
G33) and compact ring frame (Rieter K44).
 Windows-based VARIOspinData PC software is
used to transfer fancy yarn data to the machine
control system via, the RS 232 interface.
 The change between fancy yarn and standard yarn
is effected via, the machine control system thus no
need of complicated retrofitting is required.

149. YARN EFFECTS ACHIEVED WITH VARIOSPIN

150. Suessen two ply and core spun yarn:
 Suessen incorporates devices under different
trade names to spin two ply and core-spun yarn
on compact ring frame. The EliTwist® spinning
method combines compact spinning and twisting
of a yarn to get two-ply compact ring spun yarn.

151.  The EliCore® is the trade name given to spin core-spun
on compact ring frame.
 EliCore®-rigid is for corespun yarn with low elastic
elongation but high strength filament in core whereas
EliCore®-elastic is for high elongation and stand strength
filament in core.
 EliCoreTwist® is trade name given to spin two-ply (SIRO)
compact ring spun yarn.
 This attachment works irrespective of the type of top
weighting arm used and gives jerk- free movement to the
traverse motion of fibre strand and filament.
 The filament feed roller is independently adjustable in two
planes without touching the front top roller. Setting of
tension draft and traverse motion is made at a central
control panel.

152. NOZZLE RING SPINNING
 Nozzle-Ring or Jet spinning is a recent innovation, which
has until now been in the research stage.
 An air nozzle is placed below the front roller and the
issuing fibre strand passes through it before reaching the
yarn guide eye.
 The nozzle has to be placed such that the front roller nip,
the axis of the nozzle and the yarn lie in a straight line.
 Compressed air is supplied to the nozzle through pipes
with a pressure regulator and an air filter. Since the
nozzle is the heart of the process of reducing yarn
hairiness, its design plays a vital role.

154.  It is an air-vortex type of nozzle which creates a
swirling airflow as shown in figure.
 A Z-nozzle should be used for Z-twisted yarn and
vice versa.
 The Air flow issues from the nozzle in an upward
direction, i.e. against the direction of yarn
movement.
 The yarn coming from the front roller is partially
untwisted on the upstream and then re-twisted
on the downstream, i.e. the yarn undergoes a
false twisting action.

155.  The air-drag forces acting on the protruding hairs
fold and wrap them around the yarn surface.
 The distance between the nozzle and front roller,
the angle of air inlets and the yarn channel
diameter play decisive roles in the efficiency of
hairiness reduction.
 An operating pressure around 0.5 bar is found to
be sufficient to reduce it.

156.  Placing the nozzle too close to the front roller
would disturb the spinning triangle and affect the
yarn formation process itself.
 Generally, the distance between the nozzle and
the front roller is around 10 cm for the best
results.
 The air nozzle preferentially reduces longer
hairs.
 The hairiness reduction may reach 50%.

157.  Nozzle-ring spinning is in its nascent stage.
Many issues have to be addressed such as
1. Joining yarns during spinning by a suitable
means.
2. Its precise positioning in the spinning region
3. Making the cost of the nozzle affordable and
4. Reducing air consumption below 0.5 bar,
before this technology can be commercialized.

158. MAGNETIC SPINNING SYSTEM
 The approach adopted by the inventors
replaces the traveller with a magnetically
suspended light weight annular disc that
rotates in a carefully pre-defined magnetic
field.
 It is claimed that this will result in super high
rotation of the disc that is robust against all
the traditional limitations of the rotating
element of spinning system.

160.  In the magnetic ring spinning system a bias flux is
generated from both permanent magnets across the air
gap, supporting the weight of the rotating disk in the axial
direction.
 In case the floating ring is displaced from its central
position, the permanent magnets will create a
destabilizing force that attracts the ring even further away
from the center.
 The control system allows the current in the system to be
controlled by feeding back information on the position of
the rotor (obtained using four displacement sensors
mounted radially to the floating ring) and adjusting the
control currents based on this information.

161. Advantages:
 Magnetic spinning works without a traveller sliding over
the ring, so there is no mechanical wear or heat
generation.
 High speeds of the rotating magnetically suspended disk
are attainable (depends on spindle rotational speed).
 Friction losses are many times less than in conventional
ring traveller system and result in lower operating cost.
 Maintenance costs are low due to the absence of
mechanical wear.

162.  Control system can be programmed for obtaining
constant tension during spinning (yarn tension could be
measured by measuring the magnetic field strength
required to maintain the disk centered).
 Eddy current produced within the system is used to
control the resisting torque of the disk in order to produce
different yarn count (conventionally, the traveller mass is
charged in order to obtain the same effect).

163. Disadvantages
 The rotating ring based on magnetic field are
unlikely to be commercialized owing to their high
cost, requirement of large spindle gauge, high
noise level, the need for regulating the start up
and shut down speeds, and the requirement of a
special roving brake to prevent material waste
during yarn breaks and piecing up.

164. CONCLUSIONS
 The ring spinning system with all the developments as
described above is undoubtedly capable of producing broad
count range of yarns having unique characteristics, at about
50 m/min.
 However, any further increase in spinning speed is a question
again and the ring spinning system still exhibits the following
limitations:
 Unable to increase the production speed beyond 50 m/min
 Unable to improve yarn regularity beyond certain range
 Relatively longer process sequence
 Process cannot be automated completely
 Small package size and
 High spinning tension at higher spindle speeds.

165. THANK YOU