Bangladesh niversityofTextiles

TejgaonyDhaka

ProjectWorkon
“AnalysisofrejectedringcopsinAutoconerWindingMachine”
Supervised

by:Dr.Mohammad

Ali

Associate Professor& HeadIndustrial

&ProductionEngineering(IPE)BangladeshU

niversitvofTextiles(BUTex)

Submittedby:

TaukirKabirTusar (ID:2011-1-

169)Dept.ofYarnManufacturingEngineering(YME)

1
Firstofall,ourgratefulnessgoestoAlmightyAllahwhogaveusstrengthandabilitytocompletetheproject
workandpreparethisreport.

Wewouldlike to payspecialthanksto Dr. MohammadAli, AssociateProfessor, Head

ofthedepartmentofIndustrialProductionand Engineering,BangladeshUniversityofTextiles,
forcontinuouslyguidingusaboutthedevelopmentandpreparationofthisreport .Hehasenrich
eduswith necessaryideasandconceptsforimprovementofthereport.

We wouldalso like to expressourheartfeltthanksto Dr. Hosne Ara Begum , AssociateProfessor &

Head of Department of Yarn ManufacturingEngineering, Bangladesh
UniversityofTextilesforallnecessaryinformationforpreparingthisreport.

WewouldliketoexpressoursinceregratitudetoMoksedAlamTonmoy,DeputyManager,BadshaTex
tilesLimited

GolamRabbani,AssistantGeneralManager,SQUARETextilesLimited who has allowed usto

work in theirorganizationin a congenialatmosphere. Theirvaluable opinion has enrichedour
knowledgeto carryoutthe projectand portraytheinformationinalogicalsequence.
Thisworkdescribesthecausesofrejectionsofrejectedringcopsinautoconerwindingmachinewithasses
sment of variousexperimentaldatas from variousquality instruments. This causesincludes
countvariation, co efficient of variation (CV%) , Thickand thin places, neps, slubs ,hairines s and
some miscellunouscauses like oil stained yarns, crackersin yarns, half andexcess full cops, coca
colashaped copsetc . Thisworkalso suggest a few ways to solve theproblemsand
toreducetherejectionrateofcopsin
anacceptablerange.Sufficientamountoffiguresandgraphsarealsoincludedheretomakethisworkmore
accurate.

3
ContentNo ChapterName PageNo

Ol Introduction 6-8

02 LiteratureReviews 9-14

03 ExperimentalWork 15-45

04 Conclusion 46-47

O5 Reference 48-49
6
Introduction
Windingisthelastprocessthatisinvolvedin
theproductionlineofaspinningfactory,speciallyintheringyarnproduction
line.Ithasanumberofparametersand variables—
embracesdifferenttechnologiesandimprovingthewindingoperationalproductivityandefficiencybyth
edevelopmentsin several sciences and fiel ds, such as machinery, materialsscience,
automationandcontrol. Onthe ringcopsobtainedfromring spinningma chine, containsa very
smallamountofyarns(approx.50- 0grams)whichisnoteconomicallyfeasiblefortradingofyarn
.Soalargerpackageformulationfromthiscopsareessential.Forsatisfactionofthatneed,awinding
machinecomesin vision of textileexperts.This makes theuse of the
subsequentmachinesbotheasierandmoreeconomical.

In autoconerwinding machine,generally 6 to8 ring cops (or bobbins)in the magazine

arewoundedup into a bigger package called cone. From this numberofcops, at first
theyarnsgetunwound, thentheyget necessary windingtension by tensionassembly of
themachineandthenfinally they arewoundedto the cone. Cleaning ofyarns are also donein this
machine byvariousseparate cleaning unitslikeEYC (ElectronicYarn Clearer) , Zenit+, Uster
Quantum,Oerlikon,LO EPFE, Uster Quantum-3, Yarn Master etc. , used in autoconermachinesof
differentmanufacturers. Variousmodernfeatureshave comewith the passage of technology
likeAutomaticSplice Initiation, Web breakdetection,Automaticknife cut off, Automaticroll
orpackage change etc. But the feedingof the ringcopsin magazinearestill done manually
byworkers.

But the operationof winding machine is not swift all thetime.It has a numberof
modemandwelloptimizedsensorsandtheyfre9uentlyrejectsringcopstobewoundinthecone.Themaintarg
etofour projectworki s to find outthereasonof therings cops ofbeingrejected bytheautoconerwinding
machine by theanalysis of rejected ring copsand also to find
outsomewaystoavoidthisunwantedsituation.
1.1 RingCops
Ring copsare thefinal package got from thering spinning machinewhichcontainsa
smallamountofyarnofadefinitecount.Thiscopscontains50-80grams(1.5-3ounces)yarns.

1.2 RejectedRingCops
Theringcopsthatarerejectedbytheautoconerwindingmachinetowoundintolargerconesduetovar
iouskindsoffaultswithintheyarnarecalledrejectedringcops

1.3 Aimofthisproject
1. Toknowaboutrejectedringcops.

2. Toknowaboutthereasonsofcopsrejectionsinautoconerwindingmachine

3. Tosortoutsomeways to slowdowntherejectionratesofcops.
2.1 Winding
Inspinning,windingistheprocessofcreatinglargeyarnpackagescalledconefromsomenumbersofsmalle
ryarnpackagescalledringcopsinordertomaketheuseofyarnin
subse9uentmachineriesbotheasierandeconomical.

2.2 Objectsofwinding
1. Topreparethebiggerpackagesfromringcops

2. Toremovespinningfaultslikeneps,hairinessofyarnetc.

3. Towaxtheyarnasfinishingprocess(ifnecessary)

4. ToimprovetheQualityofyarnsbycleaningthem

2.3 Typesofwinding
1. Spindledrive:Wherethespindleuponwhichthepackageisplacedisdrivendirectly.

a. Constantspeedwinder

b. Variablespeedwinder

2. Frictiondrive:Wherethespindleuponwhichthepackageisplacedisfreetorotateandthepackag
eisdriventhroughfrictionbythecontactofadrivendrum.

2.4 Zonesofwinding
1. Unwindingzone

2. Tensionandclearingzone

3. Windingzone

10
2.5 WorkingPrincipleofAutoconerWindingMachine
1. Inthecreelingzone,inallthewindingpositionsofthemachine,thereisamagazineofringcopswh
ichcancarry6to8ringcopsforwinding

2. Yarnfromasinglecopgoestensionandcleaningzoneofwindingmachinethroughyarnguidewhi
ch functionis to providesufficient tension to the yarn re9uired forcontinuouswindingoftheyarn.

3. Ayarncleaningattachmentispresentinthereinordertocleantheyarntomaintainthe
OptiFFIUFFI9Ualityofyarninthefinalpackage.

4. Asensorisalsotherecalled“Stoppedmotionfeeler"tocheckifthereisanybreakageofyarnorabsen
teeismofyarnduetoanyreasonlikecopswithnoyarns

5. Ansplicingmechanismis
alsopresenttheretountwisttheendsofbothpreviousandnewcomercopyarnandjoiningthembyret
wistingthereends.

.
Finallyinwindingzone,theyarnsofallcopsarewoundedasasingleyarnwiththehelpofsurfacecontactof
agroovedcylinder.

Fig2.1:WorkingPrincipleofAutoconerWindingMachine
2.6 Autoconersusedinfactoriesalongwithspecifications

Company ModelNo. Origin NoofHeads

SchlafhorstSaurer Autoconer3gg Germany 60

VIOMachine PolarM Italy

TE IS.p.A

SclafhorstSaurer AutoconerX5 Germany 60

Muratec 21C Germany 60

Fig2.2:Windingmachine
2.7 FaultsandDefectsarisinginwindingwhichformswinding
wastes
1. Formationofpatchesontheyarn.

2. Incorrectorvariablewindingspeed

3. Toomuchknotsin theyarn.

4. Variationofyarntension.

5. Dirtyortrashypackages

6. Incorrectshapeofyarnpackage.

7. Excessivefullbobbin.

.Piecingup.

9. Overlapping.

10. Twoendwinding.

11. Mixingyarnsofdifferentlineardensityi.e.ofdifferentcount.

12. Greasyanddirtyyarns.

13. Pooryarncleaningandsnarling.
2.7 Reasonsofformationofwastagesonwindingforfaulty
ringcops
1. Duetoknotsintheyarnon ringcops.

2. Remainingendsaftertyingofftheyarnsonthepackage

3. Sloughoffofyarnsfromtheringcopsduetovariationofyarntension.

4. Remainingcoilsontheyarnpackage.

5. Droppedshortendswhilethreading.

6. Greasyordirtyyarnsintheringcops.

7. Negligenceofworkersworkingin thewindingdepartment.

Theamountofwastagedependsuponthesizeofthespinningbobbinandbreakagerate.
Withtheincreaseofpackagesizeandreducedofbreakagerateofyarn,wastageofwindingisreduced.
IS
3.1 Ringcopscollection
Ring cops sampleswerecollected fromeach of theautoconerwindingmachine . Thecollection
of this copsare doneonthe basis of threepoints, one of them is either they arereject by
theautoconeror notand the second oneis if the yarn inring spuncops are of spunfromstaple fibres,
filamentsoranyspecialblendsofnaturalormanmadefibres, thirdoneis
iftheyareanytypeofspecialyarnslikecorespun,SIRO,mélangeorconventional10 D
/natural
ormanmadefibreyarn.

Sothesampleiscollectedonthebasisof—

A. Eitherrejectedornotrejectedbytheautoconer.
B. Specificationofthe yarn present in ringcops in that sense of their origin of fibreslike100%
naturallike cotton, 100% manmadelike polyester or if thereis any blend of thetWO.
C. Thetypeofyarnthat meansiftheyarenormalringspunyarnortheyareringspunbut
ofspecialtypesofyarns.

16
3.2 Procedureofthework
Aftercollection of samplesof ring cops, we went to thequality departmentof our factory toassess
the type of fibresused in the yarnsof differentcops and also to sortout thecausesthat hasgiven
rejectionof the copsin the autocoro. Andsome additionaltests are also executed to find
thecausesoftheirrejections.

Test1:UsterAFIStest

Tofindoutthenepspresentintheyarnandalsotofindouttheaveragelengthoffibreandthemat
urityoffibres

Test2:DYNAJETtest

Tofindouttheweakpointspresentintheyarn

Test3:TectechnoCOVATEST

To findouttheirregularity, hairines sand imperfectionindex(IPI), unevennes sU

% ,Coefficientifvariationofmass(CVmD/D)oftheyarns

Test4:Autostretch5Ctest

TofindouttheCSPvalueofdifferentyarnsbyfindingouttheirindividualleastrength

Test 5:MAG-SITRAEleTrashtest

Tofindoutthetrashcontentpresentinourcollectedsamples

Test6:MESDANLABAutotwisttest

TogettheTPIandTPMvalueofsamples

Test7:YarnCounttest

Torecheckifthereisnocountvariationsinoursample
3.3 Causesofrejections
Aftergettingallofourtestresultsinhand,wewentforacomparativeanalysisoftherejectedcopswith the
accepted oneswith the help of the personnel‘sof Quality departmentof thefactoryandgetanumerous
causesofrejectionsandtheyaredescribedinthenextarticle.Wealsotriedto
gotothebackwardoftheproductionlinetofindoutthecausethatmadetheyarnintheringcopthatfaultysoitw
asrejectedbytheautoconerwindingmachine.

3.4 Desprectivediscussionofthecausesofrejection

3.4.1 Count Variation

Atfirstthreeringcopsfromthesamemagazineofthesameautoconertestedandfoundthat
theywereof two differentcountsthatmeans two different linear density yarns. When
twocopswerewoundedon the cone and autoconerstartedto fetch the yarnof thethirdcop ,
thesensorsdetectedthevariationofthecountsandsoitrejectedthecop.

Causes

1. Negligenceofworkers inthewindingsection
2. Negligence of workersof any previoussections like carding,drawing,simplex, ringetc.
sections that they mixed up differentproductswhichdidn‘tmatchedto
theproductionplanandschedule.

ExperimentalData
Table:3.1

SampleTvpe CountorLinearDensity Result

CardedYarn 30Ne Accepted
CardedYarn 30Ne Accepted
CardedYarn 32Ne Rejected
 Remedies

1. Carefulmonitoringofall
segmentsofproductionlinefromblowroomtofinalwinding.
2. Recruitmentofexperiencedand well trainedworkersin all the segments so that
thistypeofunwantedincidentsshouldneveroccour

3.4.2 ProductTypeVariation

Once aga in we tested threeringcops fromcollectedfrom thesame magazineandtested

themforany producttype variation, twoofthem wereacceptedby the machineandonewas rejected.
And we foundtwowerecarded yarn butthe thirdonewas combedyarn, butofthesamecounts.

Causes

1. Negligenceofworkers inthewindingsection
2. Negligenceofworkersofanyprevioussectionslikecarding,drawing,
simplex,ringetc. sections that they mixed up differentproductswhichdidn‘tmatched
to theproductionplanandschedule.

ExperimentalData
Table:3.2

CountoftheSample YarnType Result

26Ne Carded Accepted
26Ne Carded Accepted
26 Ne Combed Rejected
 Remedies

1. Carefulmonitoringofallsegmentsofproduction linefromblowroomtofinal
winding.
2. Recruitmentofexperiencedandwelltrainedworkers inallthesegmentsso
thatthistypeofunwantedincidentsshouldneveroccour.

3.4.3 LowCopContent

We tookcops from the same magazine and measured there length using wrap reeland
found that the rejectedone has lower cop contentthan the accepted ones that
meanslowamountofyarninweightthantheacceptedones.

Causes

1. Underutilizationofbobbinheightinringframe
2. Lowernumberofcoils/inch
3. Higherchaselengthinringframe
4. Copbottombracketproperlynotsetinringframe
s. Improperselectionofratchetinringframe
6. Ratchetpawlpushingnumberofteeth's/movementintheratchetwheel
7. Spinningemptieswallthicknessishigh

ExperimentalData

Table:3.3

SampleSpecifications CopContent Result

30 NeCombedHosiery 58gm Accepted
30NeCombedHosiery 58gm Accepted
30NeCombedHosiery 58gm Accepted
30 NeCombedHosiery 58gm Accepted
30NeCombedHosiery 28.2gm Rejected

20
 SampleVsCopContentGraph
70

60

50

.
20

30NeCombed 30NeCombed 30NeCombed 30NeCombed

30NeCombedHosieryAcceptedHosieryAcceptedHosieryAcceptedHosieryAcceptedHosieryRej
ected
Samples

Graph3.1:SampleVsCopContent

Fig3.1:Lowcopcontent
 Remedies
1. Optimumchaselength,coilspacingandwallthicknessofemptycops tube
ensuredinringframe
2. Ratchet/pawlmovementtobeproperlyset
3. Freespaceofonly7.5mmtobemaintainedatthetopandbottomof thecop
4. Freespaceonly0.75mmonlytobemaintainedbetweenfullcopsandthering

3.4.4 Neps
We tested some accepted and rejectedcops by the autoconer windingmachine
andfoundthatsomecopsarerejectedduetopresenceofexcessivenepsontotheyarns.Thistestis
donebyUster AFIS Tester. Ingeneral , neps are accepted to acertainlimit, abovethat limit it is
rejected( exceptionalis neppyyarn, whereneps aregivento yarnat apredetermined fashion)

Causes
1. Accumulationofflyandfluffonthemachineparts.
2. Poorcarding
3. Defectiveringframedraftingandbadpiecing
4. Improperlyclothedtoproller cleaners.

ExperimentalData

Table3.4

Sample Neps/km Neps/km Neps/km Result

Specifications
+140% +200% +280%
34NeCarded 782. 19a. 32. Accepted
Woven
34NeCarded 78a.8 199.2 33.2 Accepted
Woven
34NeCarded 789.2 201.53 34.25 Accepted
Woven
34NeCarded 852. 9 254.78 71.25 Rejected
Woven
34NeNeppy 912.25 927.29 Accepted
 SampleVsNeps/kmGraph
900
800
700
Neps/km

600 —
500 ■ Neps/km
400 +140X
300 — •Neps/km
200 +200%
100 Neps/km
0 +280%
34 Ne Carded34 Ne Car de d34 Ne Carded34 Ne Carde d34 Ne Neppy Woven
Woven Woven WovenY am /\c
ceptedAcceptedAcceptedAcceptedRejected

Sample

Graph3.2:SampleVsNeps/km

Fig3.2:Nepsinyarns
 Remedies
1. Properfunctioningofpneumaphil/rollercleanerstobeensured.
2. Brokenteethgearwheeltobeavoidedandpropermeshingtobeensured.
3. Betterfiberindividualizationatcardstobeachieved.

3.4.5 Slub

Slub is an abnormallythick place or lumpin yarnshowingless twist at that place .

Wetooksome copsboth rejectingand notrejecting by the machineand weretestedin
UsterAFISTester forresult.Ingeneralthis

aredirectlyrejectedforconventionalringyarns,unlesstheyarespecialyarnswhere
aregivenintentionally.

Causes
1. Accumulationofflyandfluffonthemachineparts.
2. Poorcarding.
3. Defectiveringframedraftingandbadpiecing
4. Improperlyclothedtoprollercleaners.

ExperimentalData

Table3.5

Sample Slubs/km Slubs/km Slubs/km Result

Specifications +400% M60% +520%
40NeCarded 2.59 2.7 3.12 Accepted
Woven
40NeCarded 2.42 2.77 299 Accepted
Woven
40NeCarded 2.3 2.69 2.87 Accepted
Woven
40NeCarded 3.52 3.09 2.96 Rejected
Woven
40NeCarded 15.2 14.9 14.4 Accepted
Slubyarn

24
 SampleVsSlubs/kmGraph
16-
14
12 —

mSlubs/km+400%
8

• Slubs/km+460%
4

Slubs/km
+520%
40NeCarded40NeCarded40NeCarded40NeCarded40NeCarded
Woven Woven Woven Woven Slub
Accepted Accepted Accepted Rejected Accepted
Sample

Graph3.3 :SampleVsSlubs/km

Fig3.3:Slubsinyarns
 Remedies:

1. Machinesurfacestobemaintainedclean.
2. Properfunctioningof pnemafil/rollercleanerstobeensured.
3. Brokenteethgearwheeltobeavoidedandpropermeshingtobeensured.
4. Betterfiberindividualizationatcardstobeachieved.
5. Optimumtoprollerpressure&backzone
6. Settingatringframetobemaintained.

3.4.6 Thickplacesinyarns

Thick placesare the oneof the imperfectionsofyarn thatmakestheyarn

morethickerinsomeplaceaccordingtoitslengthwisewhichisnotacceptedbytheautoconer

windingmachine.WetooksomesamplesandtestedtheminTextexchno
COVATESTTestertofindoutthisvariation.

Causes

1. Eccentrictopandbottomrollers
2. Insufficientpressureontoprollers
3. Womandoldapronsandimproperapronspacing
4. Impropermeshingofgearwheels
5. Mixingofcottonsvaryingwidelyinfibrelengthsanduseofimmaturecottons

ExperimentalData
Table3.6

Sample Thick/km Thick/km Thick/km Thick/km Result

Specification +35% +50% +70% +100%
60Ne Carded 45a 32 2 Accepted
Hosie
60NeCanded 350 40 5 0 Accepted
Hosea
60NeCanded 822 379 Rejected
Hosea
 SampleVsThickplaces/kmGraph
900
800 -
700 -
600 mThick/km
+35%
su 500
400 mThick/km
+50%
300
ThcQkm
+70%

BThick/km

6
0
N
e
C
a
r
d
e
d

6
0
N
e
C
a
r
d
e
d

6
0

N
e
C
a
r
d
e

d
H
o
s
i
e
27
 r
y 1. Eccentrictopandbottomrollerstobeavoid
A ed
c
2. Toparmpressurecheckingschedulestob
c
e eMaintainedstrictly
p 3. Widevariationinthepropertiesofcottons
t usedinthemixingtobeavoided
e
4. Betterfiberindividualizationatcardstobe
d
H achieved.
o 5. Correctspacerstobeutilized
s
i
e 3.4.7 Thinplacesinyarns
r
y
A Thin places are anotherof the
c
c imperfectionsof yarn that makes theyarn
e morethinnerinsomeplaceaccordingtoitslengthwisewhichi
p
snotacceptedbytheautoconer
t
e
windingmachine.WetooksomesamplesandtestedtheminT
d
H extexchno COVATESTTestertofindoutthisvariation.
o
s
i Causes
e
r
y 1. Eccentrictopandbottomrollers
R 2. Insufficientpressureontoprollers
e
j 3. Womandoldapronsandimproperaprons
e pacing
c
t
e
d
Sample

Graph3.4:Sam
pleVsThickpla
ces/km

Rem
edies
28
4. Impropermeshingofgear wheels
5. Mixingofcottonsvaryingwidelyinfibrelengthsanduseofimmaturecottons

ExperimentalData
Table3.7

Thin/km Result
Specificatio -50%
60Ne Carded Accepted
Hosiery
60NeCarded 2.0 Accepted
Hosiery
60Ne Carded 2512. Rejected
Hosiery

Table3.8

Sample Thick/km Thick/km Thick/km Thick/km Result

Specification +35% +50% +70%
60NeCarded 45a.0 32. 2.0 0.0 Accepted
Hosiery
60NeCarded 35a.0 400 5.0 0.0 Accepted
Hosiery
60NeCarded 850.0 672.0 12.0 516.0 Rejected
Hosiery

Remedies

1. Eccentrictopandbottomrollerstobeavoided
2. ToparmpressurecheckingschedulestobeMaintainedstrictly
3. Widevariationinthepropertiesofcottonsusedinthemixingtobeavoided
4. Betterfiberindividualizationatcardstobeachieved
5. Correctspacerstobeutilized
 Fig3.4:ThickandThinplacesinyarns

SampleVsThinplaces/kmGraph

2500 ■ Thin/km

2000

m1500 • Thin/km
-40%

Thin/km
500 -50%

• Thin/km
60NeCarded 60NeCarded -60%

60NeCardedHosieryAcceptedHosieryAcceptedHosieryRe
jected
Sample

Graph3.4:SampleVsThinplaces/km
 SampleVsThickplaces/km
900
800
700
600 ■ Thick/km
+35%
500
400 ■ Thick/km
+50%
200 Thick/km
+70%
N Thick/km

60NeCarded 60NeCarded 60NeCarde

dHosieryAcceptedHosieryAcceptedHosieryRejected
Sample

Graph3.5:SampleVsThickplaces/km

3.4.8 Imperfections
Imperfectionsare knownas thecombinationaltermofall imperfectionsofyarnslikethickplaces,
thinplaces , neps,slubsetc .It isanumberwhich isobtainedby testing
thesampleyarnsinTextechnoCOVATESTTester.Wetooksomesamplesinthistesttofindout theamount
ofimperfectionsintherejectedcops.

Causes

1. Insufficientpressureontoprollers
2. Defectiverubbercoatingofcotrollers
3. Poorcardinganddraftingefficiency
4. Olderandwomoutaprons
s. Inappropriatemixingofrawfibres
6. Misspositioningofspacer
7. Badwastecollectionsystemofthefacility
ExperimentalData

Table3.9

SampleSpecification ImperfectionIndex(IP Result

50NeCombedWoven 123.29 Accepted
50NeCombedWoven 112.26 Accepted
50NeCombedWoven 126.27 Accepted
50NeCombedWoven 269.61 Rejected

SampleVsIPIGraph

250

200

150

50

50NeCombedWoven50NeCombedWoven50NeCombedWoven50NeCombedWoven
AcceptedAcceptedAcceptedReje cted
Sample

Graph3.5:SampleVsIPIGraph
 Fig3.5:ImperfectionIndex(IPI)Spectogram

Remedies

1. Scheduledcheckingoftoprollerarmpressure
2. Widevariationoffibrepropertiesinmixingshouldbeavoided
3. Rightapronandrightspacertobeused
4. Wasteextractionandsuctionsystemshouldalwayskeepefficient
5. Higherefficiencytobetargetedincardinganddrafting

3.4.9 Unevennessinyarns

Yarnunevennes s dealswiththevariationin yarn finenes s. This is

thepropertycommonlymeasuredasthevariationofmassperunitlengthalongsidetheyarn.Weteste
dsomeoftheringcopsinTextechnoCOVATESTTesterfortheassessmentofUmD/
(Unevennesspermeters)andfoundthatsomerejectedcopshavehigherUm%
Unevennessisexpressedintwoways—
1. TheIrregularitypermeterUm%
2. TheCoefficientofvariationpermeterCvm%

Causes

1. Variationsin processedrawmaterialsgivesrisetohigherunevennessoftheendproduct
2. Variation in thespinningprocesslike in correctdraftingarrangementin
drawing,simplexand ringframe
3. Incorrectsettingofautolevelingunitinthefinisherdrawframe
4. Womoutmachinepartsinanyproductionstage
 Experimentaldata
Table3.10

Sample Irregularityper Coefficientof Result

Specification Meter(UVm%) Variation
perMeter(CVm
%)
42NeCarded 11.7 14.10 Accepted
Hosiery
42NeCarded 10.66 13.55 Accepted
Hosiery
42NeCarded 10.98 13.91 Accepted
Hosiery
42NeCarded 22.24 27.93 Rejected
Hosiery

SampleVsIPM(UVm%)Graph

25

" 5

42NeCardedHosiery42NeCardedHosiery42NeCardedHosiery42NeCardedHosiery
Accepted Accepted Accepted Rejected
Sample

Graph3.6:SampleVsIPM(UVm%)
 SampleVsCVM(CVm%)Graph

25

20

42NeCarded 42NeCarded 42NeCarded 4 2NeCar de

dHosieryAccepted HosieryAccepted HosieryAccepted HosieryRejected
Sample

Graph3.7:SampleVsCVM(CVm%)

Remedies
1. Properinspectionoftherawmaterialssothevariationintheirunevenness
remainsalwayslow
2. Scheduledobservationofallprocessinvolvedinspinningindrawing,simplexandringframe
sothatexcessivevariationcan‘toccour
3. Settingofautoleveledinfinisherdrawframeshouldalwaystrytokeepasmuch
fixedaspossibleforadefinitecountandprocess
4. Propermaintenanceactivities to checkand rectifyany mechanicaldamageshappened to
any machine part like aprons , bottom and top rollers of
drawframe,simplexandringframe,brokengearteeths,displacedchainsetc.
3.4.10SomeMiscellaneousCauses
A. SoftYarn

Someyarnsincopsareso muchsoft thattheycan‘t

bearthewindingtensionprovidedbyautoconerendingmachineandso theygot
tomoutduringwindingandas aresultthewholecop is rejected by themachine . This is the result of
containinglesser twist inthe yarnand thisis assessed in DYNAJET Tester for theidentification
ofweak pointon theyarnand autostretch SC Tester for checkingif the TPIand TPMof
re9uiredvalueis present intheyarnornot.

Causes

1. Slacktapesdirtyjockeypulleys
2. Lesstwistintheyarn
3. Badclearingatthetraveler

Fig3.6:SoftYarns

35
 Remedies

1. Vibrationofbobbinsonthespindlestobeavoided
2. Properyarnclearingtobeensured
3. Periodicreplacementofwornringsandtravellerstobeeffected

B. YarnHairiness

Yarnhairinessmeanstheprojectingorprotreudingfibresthatremainsoutsideofthe
yarn‘ssurface and thegive numerousproblemsor furtherprocessing . Excessivehairy
fibrescontainingyarns gives problemsonto windingand
sometimesthecopscontaininghairy fibredyarn gets rejected by the autoconerwinding
machine.ThishaimesstestisdoneinTextechno
COVATESTTester

Causes

1. Useoflowmaturedcottons
2. HigherMICvaleoffibresthatmeanscoarserthefibres,higherthehairiness
3. UniformityRatio(UR)lessthan50%ofthefibres
4. Inappropriatedraftingandpoororientationinspinningtriangleinringframe
5. Rubberysurfacesdamage,wornoutmachinepartsetc

ExperimentalData
Table3.11

SampleSpecification HairinessIndexH Result

60NeCardedHosiery 4.58 Accepted
60NeCardedHosiery 4.37 Accepted
60NeCardedHosiery 8.29 Rejected
 SampleVsHairinessIndex(H)Graph
9
8
7
6
05
4

60NeCardedHosiery 60NeCardedHosiery60NeCardedHosiery
Accepted Accepted Rejected
Sample

Graph3.8:SampleVsHairinessIndex(H)

Fig3.7:Hairinessinyarns

Remedies

1. Higherremovalofshortfibresincarding
2. Higherremovalofnepsincarding
3. Highercleaningandopeningefficiencyofblowroommachineries
4. Betterlubricatingofmachinepointsthatcanformstaticelectricityduring
running
C.Oilstainedyarns
Sometimesduringlubricationoranytyoeofmaintenanceworkorbyanylickagein the
lubricationsystem the yarngetsoilstained and whenitgoesto autoconeritgets rejected . We
tested some ring cops and found that some of the cops that are rejected areoilstained

Causes
1. Carelessoilinthemovingparts,overheadpulleysetc
2. Piecing'smadewithoilyordirtyfingers
3. Carelessmaterialhandlings

Fig3.8:Oilstainedyarns

Remedies

1. Appropriatematerialhandlingprocedurestobefollowed
2. Oilerstotrainedinpropermethodoflubrication
3. Cleancontainerstobeutilizedformaterialtransportation
D.Crackersinyarn
Insomebobbinsofpolyesteryarn,wefoundthereverysmallsnarl like
placeswhichdisappearedwhenwe pulled the yarnwith sufficient tensiongiven by our hands
butwhenthe tension released , this effectwasagain visible . This are called cra
ckersandonlyshowninthermoplasticmanmadefibreslikenylon,polyesteretc.Thesearealsoac
ause for bobbinrejection onautoconerwindingmachine.They are also visible
incottonpolyesterblendyarns.

Causes

1. Mixingofcottonsofwidelydifferingstaplelength
2. Closerrollersettings
3. Eccentrictopandbottomrollers
4. Nonoptimumtemperature andrelativehumidityinthespinningshed
5. Overspinningofcottons

Fig3.9:Crackersinyarn
 Remedies

1. Optimumtoprollerpressuretobemaintained
2. Mixingofcottonsvaryingwidelyinfibrelengthtobeavoided
3. Useofoptimumrollersettings
4. Useofproperlybuffedrollersfreefromeccentricitytobeensured

D.Cocacolashapedbobbins

We foundsome typeof differentshapesof bobbinsin thebasket

andcockcolashapedbobbininonepeculiarshapedbobbinanditisnamedcocacolabobbinduetoi
tsshape like acoca cola bottle.Thisshaped bobbinsaredirectlyrejectedin autoconer

Causes

1. Unevenorvariablespeedofspindle
2. Itoccursduringgivingknotstotheyarninringframe
3. Inappropriatebuildingmechanismofringframebythecradle

Fig3.10Cocacolabobbin
 Remedies

1. Alwaysmaintainingthespeedofspindleataconstantrate
2. Throughmonitoringoftheworkersnotgivingknotsinwrongfashion
3. Traintheworkersandallocatetrainedworkers piecingsection

D.ExcessiveFullbobbin

As theautocoromachinehasan input paneland in this panelit is alwaysgiven

asinputthathowmuchamountofyarnitwillbeinasinglecop.Butwhenanyexcesscopor
bobbincontaingexcess yarn is given into the magazine, after finishing
itspredeterminedlength,whenautocorowantsa newcopbutcan‘ttakeit
causepreviousonehasstillyarninit,itrejectsthepreviousexcessfullcop.

Causes

1. Spindlespeedvariationthatmeanshigherspeedthanplannedinproduction
2. Carelessnessofworkersforcollectingthefullcops
3. Improperpiecingdonebytheworkers

Fig3.11:Excessivefullbobbin

41
 Remedies

1. Alwaystokeepthespindlespeedataconstant
2. Workersshouldbemademorecarefulandskilled
3. Piecingshouldbedonebyexperiencedworkers
4. Excessive full bobbinsshould locate at the ringsection Quicklythat it
can‘tcreateanyprobleminwinding

E.Halffulledbobbins

Thisbobbinsarenotcompletelylulledthatmeanstheyarnlengthwoundedonitinthe ring
frameis almost half to the length it should be wounded.Anypartial
windingonringcopyarnsarefallen
intothistypeofbobbinsandautoconeralsorejectsallofthembecause machine can‘t
completeany onecopeinto cone thatit was comandedby thetechnicians.

Causes

1. Improperpiecing
2. Carelessnessof operators
3. Variationofcountontothesamelot

Fig3.12:Halffulledbobbin

42
 Remedies

1. Carefulandperfectpiecingofyarns
2. Carefulobservationsofmachineriessothatthereshouldnotbeany
possibilityofcountvariation
3. Sometimesonespindlestopsinaringframebutallothersrun,sothatone remaineds
toppedis surely half lulled bobbin.Soit shouldbelocatedas soon as possible
because if it goes towinding, it will mustbe rejected
byautoconerwindingmachine

3.5 Somereportsregardingwinding

A. Characteristics:60NeShortStaple
TextechnoCOVATEST

Test Um Vm Inde Thin/k Thick/k Neps/k H

No % ”A x m m m
3m -40% +35% +200%
1 1 .5 2.5 1.29 11 45 19 4.5

2 1 .23 2.57 1.29 7 4.3

7
3 1 .35 2.39 1.2 1 0 4.3
3
4 1 . 2.94 1.27 145 238 4.3
4
5 1 .53 2.1 1.31 130 405 222 4.4
2
A . 1 . 2.53 1.29 113 400 4.4

CVb 1.43 11.33 1. 4 23 12 15 2.3

D@
2
5 0.19 0.3 .03 32 1 37 0.1
% 3

43
 B. Report:AutoconerRejectRingCopsStudv

Typesof ShiftA ShiftA ShiftB ShiftB ShiftC ShiftC

rejected
ringcops Quantity Quantity Quantity Quantity Quantity Quantity

Pcs Pcs Pcs

CocaCola 2 .2 13 1.29 5 .5
Bobbin
Over 25 2.48 32 3.17 24 2.38
Piecing
FullRing 9 .89 16 1.59 31 3.08
Cops
HalfRing 12 1.19 18 1.79 17 1.69
Cops
Total 48 4.76 79 7.84 77 7.64
45
Conclusion

Windinghas importantinfluenceandaspect onspinning because itis the last step

wherespinnerscanrectifytheirfaultsifthereisanyfaultpresentinthepreviousstages.
We triedourbest todo ourprojectworkmoreaccurately . We triedto visualize
notonlytheconventionalring cardedand ring combedyarnbut also triedwithsomespecial yarns.
Wecollected ring copsfrom varioustypeofwinding machinesin thewindingsection of
theproductionfacility. We tried to keep in mind of collection of samples of same countsand
ofsameprocesses.Aftercollectingoursamoles,wetestedtheminUsterAFIS,DYN
ET ,TextechnoCOVATEST, wrap reel , MESDAN LABTester , ATOStretch5C twist tester
forvarious re9uired values to completeour projectwork like co efficient of variation per
meterCV D
/,HairinessindexH
%,imperfectionindexIPI,Nepsand contentoverlengthof
yarn, irregularityper meterUm% , thick andthin placesover variouslengthof thesamplesetc.
Notonly 9Uality parameters, butalso we have seen varioustypeof shaped
bobbinslikecocacolabobbin,halfandexcessfullbobbinsandfoundthattheyaredirectlyrejectedbythe
autoconerwindingmachine.
Wewanttofinish ourprojectworkby thankingAlmightyAllahfor giving
usphysicalandmentalstrength,ourrespectiveteachersforhelpingusbyprovidingmanytechnicaldatasan
dcarefulmonitoringand finally ourbothfactoryauthoritiesfor giving usall necessary
helpsandandfriendlyenvironment.
Reference

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4. PrinciplesofTextileTesting
ByJ.E.Booth
5. ProcessControlinSpinning
ByA.R.Grate
6. PhysicalPropertiesofTextileFibres
ByW.E.Morton&J.W.S.Hearle
7. Lectures of Dr. S.
SubramaniumAssociateProfessorandHe
adoftheIOCAnnaUniversity
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By CarlA.Lawrance
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ByB.P.Saville
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ByBYLuisHarmuth
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Website:www.muratec.net15.W
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