Insert Twist by Rotating Yarn?

Limitations of ring spinning

Technological
Yarn tension (traveller drag, balloon)
Traveller speed
Heat
Draft system

Economic Static Yarn

Large package size required (fewer

knots, fewer replacements) but larger
Twisting
package requires more power to drive
and faster traveller speed

Cause of Problem: Moving Yarn

Twist Insertion Requires Package Rotation No Twist
False
Twist Twisting

Open-End (Break) Spinning Principle Advantage of Open End Spinning

Smaller mass involved in twist insertion – higher speed

Break in Fibre Flow

No spinning balloon – lower yarn tension

Twisting

Package formation independent from twisting – larger

Fibre Winding size, choice of form, reduced winding
Transfer

Fibre Supply
Spinning direct from sliver – no roving

Brief History of Open-end Spinning Development

1876 J Hibry

USP173290 J Hibry 8 Feb. 1876

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Brief History of Open-end Spinning Development

1876, J Hibry

1937, Svend Ejnar Berthelsen

Svend Ejnar Berthelsen GB477259 24 Dec. 1937

Brief History of Open-end Spinning Development

1876, J Hibry

1937, Svend Ejnar Berthelsen

1955, ITMA Brussels, Spinnbau’s Meimberg eMKa-Spinner

Svend Ejnar Berthelsen GB477259 24 Dec. 1937

USP3119223 Julius Meimberg 2 July 1956 USP3119223 Julius Meimberg 2 July 1956

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Brief History of Open-end Spinning Development

1876, J Hibry

1937, Svend Ejnar Berthelsen

1955, ITMA Brussels, Spinnbau’s Meimberg eMKa-Spinner

1960s, Intensive R/D in many countries

Brief History of Open-end Spinning Development

1876, J Hibry

1937, Svend Ejnar Berthelsen

1955, ITMA Brussels, Spinnbau’s Meimberg eMKa-Spinner

1960s, Intensive R/D in many countries

1965, KS 200, the first machine with drafting rollers

exhibited in Czechoslovakia

1966, BD200 installed in factory

1967, ITMA Basel, Switzerland, Elitex’s BD200, 30,000 rpm

BD200b

Brief History of Open-end Spinning Development

Common requirements of open-end spinning
1876, J Hibry
Fibre separation device
1937, Svend Ejnar Berthelsen

1955, ITMA Brussels, Spinnbau’s Meimberg eMKa-Spinner Means of fibre transportation

1960s, Intensive R/D in many countries
Device for collecting separated fibres
1965, KS 200, the first machine with drafting rollers
exhibited in Czechoslovakia
Device for rotating open-end of yarn (twisting device)
1966, BD200 installed in factory

1967, ITMA Basel, Switzerland, Elitex’s BD200, 30,000 rpm Yarn take-off and package build mechanism

1971, ITMA Paris, wide spread commercial introduction Key feature of open-end spinning:
Separation of twisting from winding, but
2003 8m rotors 174.5 m ring continuous operation

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 Critical point: yarn property

Most successful system: rotor

Rotor Spinning Principle

Rotation of Yarn Arm

Inserts Twist in Yarn

Air Exit Yarn Delivery

Rotor

Nozzle Feed Roller

Fibre
Transport Opening
Channel Roller

Feed
Shoe Sliver

Trash

Opening Roller

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 Rotor

Nozzle

Example of Fibre Mass Attenuation

Feed Opening Exit of Fibre Rotor Yarn Withdraw

Roller Roller Transport Tube Groove Point

Fibre
Speed 0.015 30 100 200 2.5
(m/s)

Draft 2000 3 2 1/80

No. of Fibres
In 20,000 10 3 1.5 120
Cross Section
Yarn Arm

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 Fibre Transport Channel

Twist in Yarn: Yarn Twist t = Nr

Rotor Vd
Ny Rotation
t= Nr (rpm)
Vd Yarn Arm
Rotation
Back Doubling: t  D
Vd = (Ny-Nr)  D Ny (rpm)
Yarn Peel-off Point
Nozzle Moving Relative to
Vd Rotor =
Ny = Nr +
D Production rate (kg/h):
Yarn Delivery Speed
Vd (m/min)
Nr 1 Vd tex 1
t=
Vd
+
D Vd    60  E  N
Ignored
1000 1000
Nr Rotor Diameter = D (m)
t=
Vd
Nr Nr Nr
Back Doubling: = = D = tD
Ny-Nr Vd Vd
D

Important Rotor Parameters

180

160

140
Thousand RPM

120

100

80 Rotor Diameter
60 D

40

20

0
1967 1972 1977 1982 1987 1992 1997 2002 2007

Rotor Speed and Diameter

Rotor Diameter D
160000
Smaller rotor Higher speed
120000
Max. RPM

Must have sufficient size so that longest

fibre does not form a complete loop
80000

Minimum D > Staple Length

40000

Current minimum: 28 mm
0
28 32 36 40 44 48 52 56
Rotor D (mm)

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 Important Rotor Parameters

 : 30-60o Opening Roller Speed

 Thicker yarn:
Groove Angle Larger D & 
Higher speed gives better fibre opening

 : 12-50o
Rotor Diameter If opening roller speed is too high, fibre
D Smaller  for striping by air may not be complete, leading
Higher Rotor to more yarn faults
Speed

Optimum depends on fibre, yarn and rotor speed

Rotor Groove

Rotor Wall Angle

Opening Roller Type Working angle

Type of wire (pin or saw-tooth)

Point density

Working angle

Pin Type Saw-tooth Type

Rieter Opening Roller Wire

Draw-off Nozzle

Steel draw-off nozzle: Effects of

Draw-off Nozzle surface
For man-made fibres and blends

No static charging

Lower surface nozzle temperature Grooved nozzle increases false twist, helps to
spin yarns with lower machine twist (e.g. knitting
yarns)

Ceramic draw-off nozzle:

More hard wearing, longer life

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 Yarn rolling against
stationary nozzle surface
Effects of
Stationary Draw-off Nozzle surface
Draw-off Nozzle

Grooved nozzle increases false twist, helps to

spin yarns with lower machine twist (e.g. knitting
yarns)

Grooves disrupt fibres in yarn, increasing

hairiness and yarn faults
False Twist in Yarn
inside Rotor

Rotating Yarn Arm

Effects of
Draw-off Nozzle surface

Grooved nozzle increases false twist, helps to

spin yarns with lower machine twist (e.g. knitting
yarns)

Grooves disrupt fibres in yarn, increasing

hairiness and yarn faults

Higher false twist increase wrapper fibres

during untwisting by nozzle

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 Fibre straightening and
Loose fibre disorientate parallelization by drafting
& crimp in airflow Fibre under tension
Ring Spinning and Rotor Spinning Comparison through the process

Yarn Formation

Fibre Disposition

Fibre straightness/alignment

Wrapper fibres
Fibre hooks
develop on
Opening roller

Ring Spinning and Rotor Spinning Comparison

Yarn Formation

Fibre Disposition

Wrapping of fibre forms

Fibre straightness/alignment
when incoming fibre attached Wrapper fibres
twisting yarn arm
Fibre migration

Spinning Triangle

Front
Drafting
Rollers
Core Fibres Migrate
outwards

Surface Fibres
Under Higher
Tension
Migrate inwards
To spindle

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 Ring Spinning and Rotor Spinning Comparison

Yarn Formation

Fibre Disposition

Fibre straightness/alignment
Wrapper fibres

Fibre migration
False twist depends
on nozzle friction
Twist structure

Ring Yarn Twist

Rotor Yarn Twist

All fibres twisted

at same time
with same t
Yarn formed gradually from core outwards Highest tension
Fibres near core
Fibres deposited first (towards the core) has higher twist has lower twist angle
& under lower tension
Fibres are twisted under low tension: low fibre straightness

Twist differential & wrapping fibres make twisting testing difficult

Ring Spinning and Rotor Spinning Comparison Ring Spinning and Rotor Spinning Comparison

Yarn Properties
Yarn Formation

Tensile properties
Fibre Disposition
Evenness
Fibre straightness/alignment
Wrapper fibres Aesthetic properties

Hairiness
Fibre migration
Abrasion resistance
Twist structure
Others

Yarn properties

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 Ring Spinning and Rotor Spinning Comparison
Ring Spinning and Rotor Spinning Comparison Techno-economics
Raw material requirements Investment

Fixed costs

Operating costs
Fibre length
Raw materials/waste
Fibre fineness
Maintenance
Fibre strength Labour

Effects of drawing Energy

Product value
Impurity content
Application

Fibre type

Yarn type and end-use

Machine Example
Ring Spinning and Rotor Spinning Comparison Rieter R 40

Ring Spinning Material cotton, man-made fibres and blends up to 60 mm

Wider yarn count range Feed weight 7.00 to 2.5 ktex

Suitable for most fibre types Draft 40 to 400

Good yarn tensile, hand and aesthetic properties Yarn count 200 to 10 tex
More preparatory processes
Twist 196 to 1500 T/m
Low speed
Package weight max. 6 kg (max. 350 mm Ø)
High power requirement
Rotor Ø 28, 30, 31, 33, 36, 37, 40, 41 46, 47, 48, 56, 57 mm
Small bobbin
Opening rollers Ø 64 mm
High doffing frequency (lower efficiency/higher labour cost
Draw-off nozzles ceramic in various designs

Rotor Spun Fancy Yarns

Rotor Spun Fancy Yarns
Limited to fibre effects (mainly slubs)
Other developments
Variable motor driven sliver feed
Special opening roller (using negative
Difficult to produce abrupt changes
working angle for cotton so that fibres
accumulate on roller and produce random
Minimum length D due to back-doubling
bundles in yarn) (0.5-4 inch length slubs)

Multi-twist effects (altering yarn twist randomly)

Cover yarns

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 Cover
Core Yarn Yarn

Staple Yarn

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