Winding Rate

Winding rate is the speed at which the yarn is wound on package surface. In case of parallel package,
the traverse is very slow, so the winding rate is approximately equal to the surface speed (πDN). But in
case of cross wound package, where traverse is quick, its effect on winding rate must be taken into
account. In this case, the surface speed and traverse speed of yarn both contribute to the actual winding
rate.

The traverse velocity (VT) is at right angles to surface velocity (V S), as shown in Figure 2.1. Vector
addition of both these velocities produces the resultant winding velocity (V R). Let,
AB = Traverse speed of yarn, VT
OB = Surface speed of drum, VS
OA= Resultant speed of yarn, VR
Then,
(OA)2 = (OB)2+ (AB)2
𝑉𝑅2=𝑉𝑆2+𝑉𝑇2 ……………Eq. 2.1
If,
D = Diameter of grooved drum,
N = RPM of drum
Then,
VS = πDN
Putting values of VS in Eq.2.1, we get
VR2 = (πDN)2 + VT2
𝑉𝑅=√(𝜋𝐷𝑁)2+𝑉𝑇2…………… Eq. 2.2

Consider a grooved drum having two grooves, is driving package. If diameter of drum is 8 cm and it is
revolving at 900 rpm, calculate the winding rate, VR.
Solution:
D = 8 cm = 0.08 m
Since the number of grooves in drum are 2, its traverse will complete in 2 revolutions.
Traverse if 2 rev/min of drum = 6” / min
Traverse if 1 rev/min of drum = 3” / min
Traverse if 900 rev/min of drum = 3 × 900 = 2700” /min
Traverse if 900 rev/min of drum = 2700/39.37 = 69 m/min
𝑉𝑅=√(𝜋𝐷𝑁)2+𝑉𝑇2
𝑉𝑅=√(3.1416×0.08×900)2+(69)2
VR= 237 m/min

Set calculations
The set calculations involve the warp count, length of warp, number of ends in warp, weight of warp,
number of creels, cone weight and number of beams.
A formula to calculate the approximate number of total ends in weaver beam is given below; the
detailed formula is given later in chapter 6.
Total ends in weaver′sbeam=Ends/inch × Fabric width (inch)× No of widthNo of weaver′s beam
The number of warper beams is calculated as:
No.of warper beams=Total endsCreel capacity
No.of ends/warper beam=Total EndsNo of warper beams
Next step in set calculations is to calculate the cone length, using warp count and the cone weight. This
calculation is necessary to calculate exactly the set length.
Cone length (meters)=Warp count × Cone weight (lbs) × 8401.0936
The length taken from cone is calculated by subtracting remainders from cone length.
Length Taken = Cone Length – Cone remainder
Length taken %age=Length taken from cone (meters)Cone length (meters) ×100
Note: Normally the length taken %age is 99% for single yarns.
Now the set length is calculated using the below relation.
Set length (meters)=Length taken (meters)Noofwarperbeams×Noofcreels
The number of creels may be 1, 2, 3 or 4 depending on the requirement of set length. The amount of
yarn in terms of bags, required to warp a set of known parameters is:
No.of bags=Total ends×No.of creelsNo.of beams×Cones/bag 48
Beam count is the term used to express the count of yarn calculated using the collective amount of yarn
warped on the beam.
Beam Count=Set Length (meters)×Ends/beam×1.0936Actual beam weight (lbs)×840
The length short loss in terms of weight and %age is calculated as:
Length Short loss (lbs)=Length short (meters)×Total no of cones×1.0936Warp count×840
Length Short loss (%)=Length short (meters)Set Length (meters)×100