Winding process

2010 3rd yearTextile Engineering, Wollo university (KIOT) Page 1
PREPARATORY PROCESS OF WEAVING
Weaving is a method of fabric production in which two distinct sets of yarns or threads are interlaced
at right angles to form a fabric or cloth
Processing line in weaving mill
Spinning cop – warp yarn – winding –warping –sizing – drawing in/tying in – weaving-
Preparation of warp yarn for weaving is essential because:
 Weaving requires packages of certain build and size,
 The warp yarn must be able to withstand destructive forces to which it is subjected during
the weaving process
 The warp yarn must be sufficiently and regular in order to pass without breaking through
the drop wire eyelets, the heddles and between reed dents.
Factors that must be considered during yarn preparation:
 Package shape.
 Package density and weight.
 Yarn length on the package.
 Package identification.
 Yarn fault.
 Frictional characteristics of the yarn
Faults to be removed during yarn-preparation
 Thick place
 Thin place
 Slubs
 Lose fibers Intentional
 Count variation Unintentional
 Foreign particles (seed, slub, leaf, dust, bollworm, honeydew)
 Neps
There are two types of yarn preparation equipments:
 Single end winders, which produce packages such as cones. BTSC
 Multi-end winders, which produce packages such as beam

WARP WINDING
Winding is the process of transferring yarns from ring, bobbin, hank etc into a suitable package.
This makes using the yarn on subsequent machines both easier and more economical.
Objectives of winding process are:
 Formation of suitable package for warping.
 Checking and clearing the yarn from spinning defects
 To remove spinning faults.
 To improve the quality of yarn.
Technical Requirements of Winding Process
 The physical and mechanical properties of the yarn should not be impaired.
 Package should be built to ensure easy running off during warping at high speed.
 The package should contain maximum length of yarn.
 The yarn ends should be tied with strong knots of correct structure easily passing at
subsequent processing.
 The process should remove the objectionable fault Yarn wastes must be as small as
possible.
 The yarn tension should be regular and ensure constant winding condition
Atmospheric Conditions of Autoconer Department
In auto cone department the humidity and temperature are maintained according to the
requirements throughout the year.
Normally ranges are:
 Humidity% 55~80%
 Temperature 22~39.5℃
Four zones of winding:
1. Unwinding zone
2. Tension and
3. clearing zone
4. Winding zone

Autoconer Winding Machine Parts and their Functions
Cop holder: its function is to hold the cops for unwinding process.
Balloon breaker(anti balloon device): Its function is to break the balloon/control the length
of yarn balloon during yarn unwinding from the cop, because yarn is passes at high speed
during winding operation and hence high tension developed. Therefore that tension becomes
equalized by balloon breaker.
Eyelet guide(yarn guide): its function is to guide the yarn , To control yarn path, Minimize
yarn vibration and Reduce chance of balloon formation.
Tension devices: Tension assembly provides sufficient tension to the yarn during unwinding
from cope to winding on to cones. Due to this sufficient tension is developed on cones and
hence dense packages can be formed.

The purpose of the tension device is to allow the maintenance of proper tension in the
yarn in order to achieve a uniform package density. The tension device also serves as a
detector for excessively weak sports in the yarn which break under the added tension
induced by the tension device.
Tension device, fall into three categories:
(1) Capstan (or multiplicative) tensioner,
(2) Additive tensioner, and
(3) disc Type tensioner. KTSC
Working principle of tension devices
During the passage of the yarn through the tensing devices (left and right), the lower sensors start
to flow opposite electrons towards a coil of wire which exists inside the tensioning devices. Then
these coils of wires develop temporary opposite magnetic field and make the discs to have
opposite charge, therefore those discs attract each other and by griping at some extent gives the
required tension to the yarn. When the yarn breaks the lower sensor stop flowing of electrons
towards the coils, the temporary magnetic field will discharge and the discs replace to the
original position.
Yarn clearer: Its function is to removes the faults such as thin and thick places, neps, and
hairiness according to the set value.
 Yarn cutter: the purpose of cutter is to cut yarn
 Uster (electrical capacitance): to sense the yarn thickness and yarn faults
Working principle of yarn clearer
When thick places of yarn pass through the measuring device, the change in capacitance caused
by the change in yarn thickness is converted in voltage oscillation which is amplified and
actuates the cutting mechanism
As the spun yarn have various faults i.e. thin and thick places, neps, hairiness, embedded
particles of dust & leaves coloring matters and short and long defects etc .Its function is to
remove these faults according to the given set values on electron touch screen panel to produce
fault free yarn to meet the quality requirements.

Feeler (stop motion):it is automatic stop motion. The purpose of the stop motion is to
stop winding when the yarn breaks or runs out as well as give yarn tension and protect
yarn damage.
This stop motion varies in configuration from machine to machine but in general
consists of a counter-weighted or spring loaded sensing device which is held in an
inactive position if the yarn is present. Breakage or running out causes the absence of
this restraining yarn and allows the sensing device to activate. At this time feeler is
dropped. When it dropped the package disengaged from the drum because it contact
with the cradle.
Groove Drum: It is a polished surface metallic drum slightly cone type, having different
diameter at both sides i.e 90 mm on one side and 100 mm on other side. It has cut marks or
grooves cut in to it at its surface to help the cross winding of packages. Its speed lies in range
from 1000 to 2000 rpm. Direct drive from main motor.
Groove: - forms traverse and rotational motion
- give rotational motion to the spindle or to the bobbin indirectly (by surface contact)
- give traverse motion to the yarn by the groove
The winding density of a larger butt is greater than a smaller butt because in the larger butt the
groove drum is narrower. The larger butt is concave while the smaller butt is convex.
Cradle: Its function to provide setting to cone having package holders, it lies on upper part
of machine on drum.
 Spindle holder: to hold the cone. During doffing it change its direction after it
disengages from the drum.
 Handle bar: used to engage and disengage the package from the drum.
Conveyer belt: its function is used to remove the empty bobbin or cop.
Over head cleaner(Traveling cleaner): It moves from one end to another end of machine to
remove and blow the dust, fly and other contaminant particles and keeps winding unit clean.
disengage mechanisms.
Motor: the function of motor is used to drive the required parts of the machines.
 Over head motor; used to drive traveling cleaner.
 Mini motor: used to drive conveyer belts.
CPU (central processing unit). It is electrical circuit board which is used to control the
machines.
Winding machine stop motion during yarn breakage
 This stop motion varies in configuration from machine to machine but in general
consists of a counter-weighted or spring loaded sensing device which is held in an
inactive position if the yarn is present.
 Yarn Breakage or running out causes occur, the absence of this restraining yarn and
allows the sensing device to activate the cam shaft. At this time feeler is dropped.

When the feeler dropped the package, immediately the cam shaft moves upward the
cradle leg in order to disengage the contact of the package from the drum.
Basic Mechanisms of warp winding process
The basic mechanisms of warp winding process in BTSC are:
 Unwinding
 Tensioning
 Yarn clearer
 Package formation
1. Unwinding/Yarn Withdrawal
The unwinding process of yarn from a package is called yarn withdrawal. Function of yarn
guide. The yarn is unwind from the cop is by the rotational motion of the drum. It draw from
cone by drum speed.
2. Tensioning
The tensioning devices ensures adequate tensioning of the yarn
The needs for tensioning are:
 It gives required winding density.
 It gives suitable tension to the yarn.
 It facilitates winding.
 It aids to remove weak yarns
Tension devises classification into four:
A. Multiplicative type (Post type or Capstan)
B. Additive type
C. Disc type (Combination of additive & multiplicative type). KTSC
D. Automatic tensioner
The tension of yarn control in KTSC is by increasing and decreasing the weight of the washers
on the disc. There are bottom and upper disc type tensioning devices.
3. Yarn clearing/Slub catcher
Yarn clearer or slub catcher is a device which used to detect and removes yarn faults in order to
improve yarn quality and weaving efficiency. The yarn clearer checks the yarn thickness and
cleans it from fluff and dirt.
Faults removed by yarn clearer:
 Thick & thin places in the yarn.
 Slubs & neps.
 Loose fiber.
 Unwinding
 Tensioning
 Yarn clearer
cone by drum speed.
2. Tensioning
B. Additive type
 Slubs & neps.
 Loose fiber.
 Unwinding
 Tensioning
 Yarn clearer
cone by drum speed.
2. Tensioning
B. Additive type
 Slubs & neps.
 Loose fiber.

 Foreign matters.
Yarn clearer can be grouped in to:
i. Mechanical clearer
ii. Electromechanical clearer
iii. Electronic clearer
 Capacitance type. KTSC
 Photoelectric type
Electronic capacitance type Yarn Clearer working principle
When thick places of yarn pass through the measuring device, the change in capacitance caused
by the change in yarn thickness is converted in voltage oscillation which is amplified and
actuates the blade for cutting mechanism is occurred.
4. Package Formation
During winding the yarn undergoes two motions. It is wound around the package by the package
drive and it is given a lateral motion to cover the package by the traverse mechanism.
The traverse reciprocating along the axis of the package lays the yarn on the package.
The package density is controlled by yarn tension and the contact pressure between package and
drum.
There are two ways to drive the yarn take up package.
i. Drum winder (by surface contact) .KTSC
ii. Spindle winder (by direct drive to the package spindle)
There are three ways commonly in use to
traverse the yarn to build-up the package.
i. Cam operation
ii. Propeller or fun traverse
iii. Rotary or Drum traverse. KTSC
It becomes more popular due to the lack of speed limitation. The yarn is guided along the
traverse and back by a groove in the driving drum, which is helical (only the yarn has to change
direction). The drum is denoted as a 2- crossing drum, 2.5-crossing drum, or 3-crossing drum etc.
There are two types of package build.

i. Random winding: the coils per double traverse decrease from start to finish of the package. It
is most common and suitable for most staple spun yarn, but is unsuitable for continuous filament
or delicate staple-spun yarns as the friction contact, especially at high speeds, causes yarn
damage. The yarn package is driven by contact with a driving drum, which may be metal or
plastic. KTSC
ii. Precision winding: the number of coils per double traverse at the beginning of winding the
cone is equal to the number of coils per double traverse at the finish
Auxiliary function of winding
Creeling: creeling is the placement of full packages in position ready to be unwound as part of
the transfer operation. Alternative meaning is the removal of the exhausted packages and their
replacement with full ones. Manual creeling is done in KTSC
Doffing: doffing is the removal of the newly wound packages & usually the replacement of these
by empty packages which will receive yarn during the transfer process. Manual doffing is done
in KTSC.
Piecing: piecing is the finding & connecting of the ends on the packages. The connecting b/n
the ends can be made by splicing in KTSC. It is done automatically by using automatic splicer.
Warp winding faults and wastes
The most common defects which can occure in warp winding process are

Quality parameters of winding
 Minimum faults
 No damage of yarn
 Easy unwinding
 Suitable size and shape of the package
 Economical condition
 Avoid excess loosened and tightness
 Cheep cost of package
The key parameters in winding are:
 Slub catcher setting
 Yarn tension
 Winding speed
Productivity
The production of winding machine is determined by the weight of the yarn wound in a certain
period of time.
Types of productivity calculations:
♦ Theoretical production
♦ Actual production
The theoretical production (Pth) of one spindle (winding head) can be calculated as:
Winding machine productivity
Efficiency
It is the percentage expression of the ratio of actual
production & calculated production.
Winding efficiency = actual production x 100
Calculated production
Efficiency loss= (calculated -Actual) production x100
Calculated production

Example 1.
An automatic winding machine which has 50 spindles runs at an average speed of 1000 m/min
with an efficiency of 0.8 processing a 20 tex yarn.
(a) Calculate the actual production of the machine per shift of 8 hours
(b) (b) How many packages of cones will be produced per day if the weight of each package
be 2.5 kg?
(c) What would be the average length of yarn wound on each package?

Winding process

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