Educational course for Frame Textile Group South Africa, Liberec September 2006

Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Fiber to Yarn Engineering

Part VI: Spinning Technology

Sayed Ibrahim
Technical University of Liberec, 46117
Liberec, Czech Republic
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

The Roving Frame

The roving frame is a necessary evil

•The draft needed 300 to 500

• Draw frame cans represent
the worst mode of transport
• The roving frame itself is a
complicated, liable to faults,
causes defects.
•automation of the machine
• is very difficult
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Demands Placed upon Modern Roving Frame

•Design of simpler machines, less liable to faults;

•Increasing in spindle rotation rates,
•Large packages,
•Automation of machine and of package transport
Tasks of the roving frame:
•Attenuation the sliver to a fine strand
•A protective twist must be inserted, that the roving can be
wound on a package transported
•Roving winding makes the roving frame relatively complex
•winding requires in addition to the spindle and flyer, a
cone drive transmission (or variable gear), a differential
gear and a builder motion.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Arrangement of Bobbins

Effect of the arrangement of bobbins in

two rows:
•This arrangement is economical in space,
•Leads to different angels (alpha),
•This leads to different rolling
conditions at the entry point
of the roving to the flyer top
•Difference in the
angle (Beta) swept
out by the two
rovings at the
front cylinder
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Draft Arrangement

The drafting arrangement:

•3 over 4 arrangements is found
relatively rarely
• Double apron system is standard.
•Double apron arrangement enables
drafts of 20 and higher
•In general 3 over 3 are used Break
drafts are usually selected around 1.1,
(1.05 to 1.15) for cotton and slightly
higher for synthetic fibers
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Various Drives of Flyers

Spindle mounted flyers Top mounted flyers Closed flyers

Rieter offers two new roving frames, F15 with manual doffing and F35
with automatic doffing. Both models are available with gauge 110 and
130 mm. The roving frames are characterized by easy operation, great
reliability, high flexibility and reduced operational cost.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Cone Drive Transmission (elder types)

 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Auto-doffing

Touch screen with 10 inch display., setting all working parameters

directly on the panel, Electronic control of roving tension, roving
ends-down control with optical sensors on each spindle,
SEPARATE servo drives for flyers and spindles.
Pneumatic loaded weighting arm for equal drafting pressure at
highest roving evenness over the whole machine.
Positive drive feeding creel, Less maintenance due to electronics.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

The Ring Spinning Frame

The American Thorp invented the ring-spinning
machine in year 1828. In 1830, Another
American, Jencks contributed the traveler
rotating on the ring. During the last 160 years,
the machine has passed many considerable
modifications, but the principle of yarn forming
remained unchanged. In spite of the many yarn
forming introduced, the ring spinning frame will
continue for some time for the following reasons:
It is universally applicable, i. e. processes any
material for any count, quantities.
•It delivers a yarn with optimal characteristics
(regarding structure and properties).
•It is uncomplicated and easy to master,
•The know-how for operation is well established
and friendly use.
•It is flexible as regards (blend and lot size.)
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Basic Principle of Yarn Forming

Basic Principle of Spinning:

•Drafting mechanism
•Consolidation mechanism
•Winding and package
forming mechanism.

•The ring spinning is

characterized by two main
features:
•1) Continuity of fiber flow
roving to yarn.
•2) Tension-controlled
spinning process.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Principle of Twist Insertion Mechanism

In practice, spindle speed

(rpm) is used instead of
traveler speed (rpm) in the
above equation; this results
in a slightly over-estimated
nspindle
value of twist because nspindle
is slightly greater than
ntraveler. The difference in
speed between spindle and
traveler causes the yarn to
wind on the package. The
increase or a decrease in
twist is mainly a result of a
change in the speed of the nspindle ( rpm )
delivery roller. Thus twist Twist = Turns / meter ( t . p.m ) =
Vdelivery ( m / min)
level affect productivity.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Basic Relationships Between Different

Ring-Spinning Parameters

Suppose that traveler speed is 40

m/sec, and the ring is 45 mm, the
rotational speed of the traveler is
Vtraveler = π d ring ntraveler
40(60) = π (45 /1000)ntraveler
40 x 60
ntraveler = ≈ 16976 rpm
π (45 / 1000)

twist required in the yarn is 20 tpi

ntraveler 16976
V yarn = = ≈ 849 inch / min (or 21.6 m / min)
tpi 20

For a bobbin diameter of 1.3 inch, the

winding speed nwinding is :
V yarn = π d bobbin nwinding
Note, if twist increased to 25 tpi, the yarn
Thus, the winding speed is given by: delivery will be reduced 849 inch/min to 679
V 849 inch/min. the winding speed is reduced from
nwinding = yarn = ≈ 208 rpm
πd bobbin 1.3 π 208 rpm to 166 rpm, which affect production
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Limitation of Speed

ntraveler ntraveler
Twist = V =
The twist is given by: Vdelivery and delivery
Twist Accordingly, increasing the delivery
speed or productivity of ring spinning should be discussed in relation to traveler speed.
In other words, any increase in productivity must be through an increase in traveler
speed. High traveler speed will result in traveler burning out due to the frictional heat
generated between ring and traveler. The main two forces acting on the area of contact
are: the centrifugal force 2
and the frictional force . The centrifugal force can be expressed
as: 2 m * V
CF = t t

d ring
Where = mt traveler mass, = Vt traveler speed, and = d ring ring diameter.
The normal force acting on the traveler during rotation may be approximated by the
centrifugal force. The frictional force is then: 2
2miVt
F = μr / t * CF ≈ μr / t
d ring
Where, = μr / t the coefficient of fiction between the ring and traveler. The frictional heat
may be described by the thermal load capacity of the ring/traveler system. In order to
assess the limit of the thermal capacity of a ring/traveler system, investigations used the
critical pressure exerted by maximum normal force between the ring and 2 the traveler.
This pressure is expressed as follows: CF 2 m .Vt max
Pr / t ≈ max or Pr / t ≈
i

Where Ar / t is the area of contact Ar / t d r . Ar / t

 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Traveler Speed/Spinning Tension

Relationship I

Spinning tension is defined as the

tensile force applied on the yarn at the
onset of twisting: that is the yarn
tension at the point where the fibers in
the spinning triangle are being twisted.
The critical importance of this
parameter lies in the fact that it
contributes largely to both the quality
of ring-spun yarn, and the spinning
performance. Spinning tension results
in a closed packing of fibers during
twisting, which enhances the yarn
strength. Variation in spinning tension
directly results in variation in yarn
strength. Excessive tension or tension
peaks may result in end breakage
during spinning. In fact, more than
80% of end breakage during ring
spinning is believed to result from
tension peaks at the spinning triangle.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Traveler Speed/Spinning Tension

Relationship II
The relationship between traveler speed and spinning tension can be demonstrated by the
following equation (Stalder, 1991):
2
μr / t mt .Vt
Ty =
sin α d r
where µr/t = the coefficient of friction between ring and traveler, a = the angle between yarn from
traveler to bobbin and a straight horizontal line from traveler to spindle axis, mt = traveler mass,
Vt = traveler speed, and dr = ring diameter. Note that the term (mt. V²t / dr) represents the
centrifugal force discussed earlier. This equation clearly indicates that the increase in traveler
speed will result in an increase in the centrifugal force, and consequently, an increase in the
spinning tension. In practice, an increase in spinning tension above a certain critical limit will
immediately result in end-breakage
(i) the spinning tension or the tensile force applied on the yarn at the onset of twisting, (ii) the
balloon tension or the tensile force applied on the yarn as it enters the ring/traveler zone, and (iii)
the winding tension or the tensile force applied on the yarn during winding.
The three tension components must act precisely to maintain the stability of the yarn balloon,
which is a critical requirement for acceptable spinning performance. Among the three, spinning
tension is the most interactive component with the input fiber strand. This is because of its impact
on the fibers being delivered from the nip of the front roller (fibers in the spinning triangle). More
discussion on this point is given below.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

The Spinning Triangle I

In the spinning triangle, different fibers have different tensions

depending on their position in the triangle. When fibers are
released from the nip of the front roller, those exhibiting high
tension tend to move toward the center displacing the initially
central fibers to the outer layers. This phenomenon is called
"fiber migration" and its main effect is to enhance fiber cross-
linking, and consequently to improve yarn strength.
The dimensions of the spinning triangle (width and height)
determine the extent of fiber/machine interaction in this critical
zone. the width of the triangle is a function of the amount of
draft or the total number of fibers delivered, and the pressure on
the front roll. The height of the triangle, on the other hand, is
quite sensitive to the spinning tension.

three different fiber arrangements in the spinning triangle

n1 = fibers which are only held at one end by the nip of the front roller while the other end is free
· n2 = fibers which are only held at one end by the twisting point while the other end is free
· n3 = fibers which are held by both the nip of the front roller and the twisting point (i.e. fibers
firmly held by the triangle). Those fibers exhibit a mean fiber length longer than the height of the
spinning triangle.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

The Spinning Triangle II

Any fiber entering the spinning triangle that does not belong to any of the above
categories will typically be too short (fiber fragment) and, if not held by other
fibers, will likely result in fly generation.
Two forces are acting against each other; the spinning tension Ty and the fiber
strength Tf. Perfect dynamic balance is achieved, if all fibers in the spinning
triangle will equally share the support of the spinning tension. (all fibers in the
triangle belong to the n3 group). If the majority of fibers in the triangle belong to
the other two groups, a smaller number of fibers will be supporting the load
exerted by the spinning tension. This situation may result in tension peaks and a
spinning failure or end breakage at the spinning triangle.
The spinning triangle should have optimum dimensions to allow spinning
stability. In particular, the triangle should not be too small to provide a room for
fiber exchange of position (fiber migration), and not too large to allow the
majority of fibers to be held in the triangle (high hairiness). This latter point was
the driving force of a new ring-spinning development called the “compact”
spinning.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Twist Level I

The twist level in the spun yarn be large enough to provide maximum yarn strength, yet as
small as possible to provide yarn flexibility and optimum fiber compactness.
Two critical characteristics: strength and comfort.
the optimum twist level is determined by
the intersection of two curves: the strength-
twist curve, and the comfort-twist curve.
comfort is expressed by an index from zero
to one, with zero indicating high
discomfort, and one indicating the highest
possible comfort level. In case of the
strength-twist curve, the strength index
implies the ratio between the actual
strength produced at a certain twist level
and the maximum strength that can be
obtained from the spinning system used
and the fiber characteristics utilized.
In practice, obtaining an optimum strength/comfort combination requires two basic conditions:
• Appropriate selection of fiber characteristics
• A spinning system that can produce acceptable yarn strength at the lowest twist possible
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Twist Level II

With regard to fiber characteristics,

the strength-twist relationship is
influenced by many fiber properties.
These include fiber length, fiber
strength, inter-fiber friction, and fiber
fineness. For a given yarn count, the
maximum strength can be obtained at
lower optimum twist when fibers of
high length, high strength, high
friction, and low coarseness are used.
This is due to the fact that longer,
stronger, and finer fibers will provide
higher yarn strength by virtue of their
effective contribution to yarn
structure. In addition, long and fine
fibers are flexible under torsion. This
means that they provide minimum
resistance to the mechanical twist
applied during spinning.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Twist Level III

With regard to the comfort-twist

relationship, many fiber
characteristics contribute to the
make of such relationship. In
general, longer and finer fibers are
expected to produce yarn and fabric
of better handle due to high fiber
flexibility, particularly under
bending. In addition, fibers of low
flexural and torsion rigidity will also
result in better fabric handle.
On the thermo-physiological side,
appropriate levels of fiber length and
fineness should be used to provide
optimum fiber compactness. Other
properties related to this aspect of
comfort include moisture content
and fiber density.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Relationship between Traveler Speed and Spindle

speed at Different Ring Diameter
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Relationship between Production and Spindle

Speed
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Demands on Modern Spinning Frame

Flexible and easy production of quality yarns:

Ex. Rieter, introduced the so-called FLEXdrafing system, which enables
to produce constantly the required quality level. Yarn count and twist
can quickly be changed to new conditions at the push of a button.

FLEXdrafing system

Setting at the control panel

Centralized Frequency motors

Spinning in quarters Easy to change

 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Demands on Modern Spinning Frame

Cops Change system: The SERVOgrip clamping

crown for clean doffing process with minimum of fiber fly.
No underwinding is needed.No yarn loss, cleaning after
doffing is not more necessery.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Demands on Modern Spinning Frame

Automatic Doffing:

ROBOdoff
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Demands on Modern Spinning Frame

Fully integrated monitoring doffing process

 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Cop Handling I

Cop Transport system:

The doffer transports the full cops to the SERVOdisk transport
system, which conveys them to the transport station of the
winder or the fully automated ROBOload tube loader.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Cop Handling II

The ROBOload is reliable, fully automated yube and cops handling

system. Full packages and empty tubes mounted at a rate of up to 40
cops per minute.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Monitoring and Control

Parameters such as rail lift or spindle

speed or components such as drafting
system bottom rolls, have an impact
influence on spinning process.
Continuous monitoring through the the
spinning process ensures yarn count
consistency. Sensors needed for this job
are integrated with the devices.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Integrated Cooling System

The system INTERcool from Rieter feeds the

heat from all motors and frequency
converters directly to the air conditioning
system via an internal heat exchanger. This
considerably reduced the load on the air
conditioning system. The heat generated are
prevented from circulating inside the mill
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Individual Spindle Monitoring System ISM

The Individual Spindle Monitoring

system make it easy for the operator
to find the ends down quickly. This
is provided by a navigation system.
Each spindle has its sensor for
monitoring ends down and other
interruptions. A report for the whole
machine is available.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Modification of Ring Spinning

1 – Compact Spinning
2 – Siro Spinning System
3 – Core Yarn Spinning
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

The Compact (or Condensed) Spinning

Compact or condensed spinning is a new
concept of yarn forming. It represents a
fundamental modification of the
conventional ring-spinning system that
aims at producing a better surface integrity
of spun yarns and maximizing the fiber
contribution to yarn strength. The idea
stems from the point made earlier about
the necessity of controlling the dimensions
of the spinning triangle to improve yarn
strength and reduce yarn hairiness.
the width of the fiber strand undergoes dynamic changes as fibers flow from the drafting
zone to the twisting zone. The continuous change in the width of fiber strand under the
draft roll (Wf) to the width of the spinning triangle (Wt), associated with the tension
differential across the fiber flow result in a divergence of some fibers (particularly, the
edge fibers) from the main fiber stream. This prevents some fibers from being fully
incorporated in the yarn structure and does not contribute to yarn strength and more
likely form protruding hairs. The difference (Dw) between WF and WT increases as the
speed of the front roller increase; this is due to less control on fiber draft and spinning
triangle width.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Principle of Compact Spinning

Conventional RS
1)Draft arrangement
1a) Condensing element
1b) Perforated apron
VZ Condensing zone
2) Yarn Balloon with new
Structure
3) Traveler,
4) Ring
5) Spindle,
6) Ring carriage
7) Cop,
8) Balloon limiter
9) Yarn guide,
10) Roving
E) Spinning triangle
of compact spinning
Compact RS
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Factors Affecting Compact Spinning

Condensing zone is heart of

compact spinning.
Fiber length, fineness and
stiffness are factors affecting the
fiber transport by air flow, this
necessitates apron moving to be
less than delivery rollers
(condensing) .
Changing the perforation width
increases air velocity.
Smooth guides gives better twist
propagation.
Hairs of less than 2mm
give better cover factor,
Hairs> 3 mm are
Problematic for processing
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Principle of Different Compact Systems (Rieter,

Zinser and Sussen)

Suction element
Suction element
Suction element

Rieter compact system Zinser compact system Sussen Compact system

Perforated Cylinder Perforated Apron Lattice Apron

Different Compact Spinning Systems

 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Rieter Com4 Compact Spinning System

The Condensing zone

The Com4 system was conceived by Dr. Ernst
Fehrer, the founder of friction spinning. The
condensing system of Rieter consists of a Perforated rollers
perforated drum, just situated after the double
apron arrangement and works simultaneously
as a delivery roller of the draft system. On the
perforated drum, two pressure are situated. The
first roller acts as nipping point of the draft
system, while the second roller works as twist
stop to prevent twist escaping to the condensing
zone. The fiber bundling occurs through the
suction zone, which is found inside the
perforated roller, and in the region between the
two pressure rollers. Under this air suction ,
fibers merging from the delivery nip of the
drafting unit are held against the drum surface
and moved at the same circumferential speed as
the drum surface. In ATME 2000 Rieter south
Carolina introduced an innovation in the air
guide providing more fiber compactness both
against the drum and in lateral direction. This
innovation is known as K44-C.om4. Details of Compact Spinning
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Sussen Elite Compact Spinning System

Suessen compact system consists of a tubular
profile, subjected to a negative pressure and
closely embraced a lattice apron. The delivery top
roller fitted with rubber cots, presses the lattice
apron against the hollow profile and drives the
apron, at the same time forming the delivery
nipping line.The tubular profile has a small slot in
the direction of the fiber flow, which commences
at the immediate vicinity of the front roll nipping
line in the region of the delivery nipping line. This
creates an air current through the lattice apron
via the slot towards the inside of the profile tube.
The air current seizes the fibers after they leave
the front roller nipping line and condenses the
fiber strand, which is conveyed by the lattice
apron over a curved path and transported to the
delivery nipping line. As the slot, being under
negative pressure, reaches right up to the delivery
nipping line, the fiber assembly remains totally
compacted. This results in a substantial
disappearance of the spinning triangle.
1) Profile tube, 2) Lattice Profile tube with
apron, 3) Delivery top roller inclined lattice apron
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Zinser Compact System

The system of Zinser, is characterized by

extending the draft system by a double roller.
A perforated apron is moved over the upper
roller, where the suction profile element is
found. Between the delivery roller and the
perforated apron, the condensing zone occurs.
The roller pair is working in a classical way as
in ordinary draft system.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Siro Spun Twofold Yarn

The SiroSPUN™ process adapted some of the

self-twist discoveries of CSIRO to the ring
spinning technology of the worsted system, and
combined spinning and doubling in the one
operation. The technology maintains two separate
strands during the spinning process, and this
allows a number of fiber-binding mechanisms to
operate before the strands are twisted about each
other. An important aspect of the SiroSPUN™
system is a simple device to break out the
remaining strand if one of the strands should be
accidentally broken. SiroSPUN™ is used also for
short staple fibers as cotton and blends. The
roving strands, which are drafted parallel, are
combined after passing the front rollers at the exit
from the drafting system, with some twist being
produced in the individual strands right up to the
nip point. Once past the front roller of the drafting
system, the two strands are combined producing a
twofold-like yarn. The yarn has uni-directional
twist like a singles yarn but the fibers are bound
sufficiently for the yarn to survive weaving.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Multi folded Threads

Siro-core compact yarn

To achieve higher quality requirements, multi folded threads are manufactured on

compact yarns twisted together.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Different Types of Multi Folded Yarns

Siro Yarn Single yarn compact Plied Multi Plied compact R.S. Plied
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Core Spun Yarn

Core Spun Yarns are

produced on Ring Spinning
machines or Compact R.S
Machines. Essentially is
adapting the tension of the
filament yarn. Also the
percentage of Core/ sheath
determine the yarn
characteristics.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Non-Conventional Spinning Systems

1 – Open end Spinning

2- Core Spun Rotor Spinning (Rotona)
3 – Air Jet Spinning
Murata Air Jet Spinning
Murata Vortex Spinning
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Principle of Open End Spinning

In rotor spinning, the drafting mechanism

consists of three main operations: (i)
mechanical opening using an opening roll, (ii)
air drafting using an air stream and
transporting duct, and (iii) doubling
mechanism. The mechanical drafting is
achieved using a toothed opening roll. In order
to minimize fiber disorientation, the airflow in
the duct should have a velocity exceeding that of
the surface speed of the opening roll. To obtain
such an airflow, the inside of the rotor is run at
a vacuum which may be achieved by designing
the rotor with radial holes to allow the rotor to
generate its own vacuum (self-pumping effect).

The continuity of mass flow in rotor spinning

is determined by the following equation (Lord, 1981):
M fibers = M yarn
Mfibers = the mass of fibers in the air duct, Myarn = the mass of output yarn, Vf =
fiber velocity, Vy = yarn velocity, ndf = the number of fibers in the air duct at the ndf tex f V f = n yf tex f V y Δ
inlet of the rotor (<10), nyf = the number of fibers per yarn cross-section. The
above mass-flow equation indicates that the number of fibers per yarn cross- n yf Vf
section is a function of the number of fibers landing inside the rotor, fiber Thus , =
ndf Vy
velocity, and the yarn velocity.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Factors Influencing Rotor-Spinning

Performance I
Rotor-Yarn Structure :
The low tension, and the subsequent lack of torque control results in a structure that is unique for
rotor-spun yarns. In general, this structure consists of a core, which is fully twisted (similar to ring-
spun yarns), and an outer-layer that is partially twisted. In addition, some fibers called "belly or belt
fibers" are randomly deposited on the yarn surface. These fibers result from the interfacing between
the processes of laying fibers on the rotor-collecting surface and the peeling off of the yarn from the
collecting surface (see previous Figure). This interface occurs once per each rotor revolution. These
bellybands are laid at these times; they may take a clockwise or an anti-clockwise direction.
As a result of the partial true twist in rotor-spun yarns, the yarn has a natural curling (or snarling)
tendency, similar to ring-spun yarns. The major difference, however, lies in the fact that in rotor-spun
yarn, the natural torque resulting from the real twist is partially balanced by a torque caused by the
wrapping effect of the belly bands.
The curling tendency can be determined by the residual twist or the difference between the measured
yarn twist and the nominal twist ( Δ T ). The assumption made here is that the higher the value of *T,
the lower the curling tendency, and the higher the number of bellybands or the higher the level of their
tightness. Typical Δ T values may range from 10% to 40%. Using this value, Artzt et al examined the
cause and effect of curling tendency and made the following important points:
• The main spinning parameters influencing the twist difference (or curling tendency) are rotor
speed and rotor diameter (or the ratio of rotor diameter to fiber length, dR/FL).
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Factors Influencing Rotor-Spinning

Performance II

• The increase in rotor speed generally results in an increase in Δ T or a decrease in the

curling tendency, for all rotor diameters. For a given level of twist, rotor speed was independent
of the number of bellybands. Therefore, the decrease in the curling tendency with the increase in
rotor speed was attributed to an increase in the tightness of bellybands rather than their
frequency.
• The decrease in rotor diameter was generally found to increase the twist difference, or decrease
the curling tendency.
• The steadily increase in rotor speeds leads to ever smaller rotors with the consequence of
greater fiber randomness, less control on fibers in the flight path, more fiber bellybands, less
curling tendency, and, consequently, more shift away from the structure of ring-spun yarn
structure.
• For a given spinning condition, yarns with high curling tendency also display high yarn
extensibility by virtue of their "liveliness". In general, yarns with only 5% elongation are
practically "dead". They also lead to finished articles with very little elasticity. The low
extensibility has an effect on the fabric tearing strength in that the low extensible yarns are not in
a position to build up a corresponding network of force distribution. When tear stress is applied,
the individual threads are virtually stressed one after another, which leads to a corresponding low
overall tear propagation strength.
• Yarns with high curling tendency are generally difficult to handle in weaving and knitting
processes.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Factors Influencing Rotor-Spinning

Performance III

Effect of Rotor Speed:

•The delivery yarn speed in rotor spinning is determined by the rotor speed and the amount of
twist inserted: V nrotor Accordingly, the increase in yarn linear speed (or the production
=
rate) requires yarn twist an increase in rotor speed.
•In comparison with ring spinning, this represents less of a challenge because of the much
smaller rotating mass than the spindle carrying the yarn package. In the early generation of
rotor spinning, the increase in rotor speed was hindered by mechanical limitation. From 1967 to
2000, the rotor speed was increased from 25,000 rpm to 150,000 rpm. This dramatic increase was
associated with a simultaneous reduction in the rotor diameter and with more innovative rotor
bearing systems.
•Recall that according to equation of mass flow, the ratio between the number of fibers in the
yarn and those at the inlet is determined by the ratio between the fiber velocity and the yarn
velocity (nyf/ndf = Vf/Vy). If the fiber velocity is approximately equivalent to the surface speed of
the rotor (Vf . VR = %dR nR), the ratio nyf/ndf will be approximately equal to %.dR.T, where T is
the twist in tpi. This means that the number of fibers per yarn cross-section is determined by the
amount of twist for a given rotor diameter, and the number of fibers entering the rotor. Also
recall that the ratio nyf/ndf represents the number of back doubling in the process, which means
that the level of twist (nR/Vy) and the rotor diameter determine yarn uniformity.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Factors Influencing Rotor-Spinning

Performance IV

Spinning Tension:
•Several equations have been developed to describe the yarn tension during rotor spinning. The Rieter
group proposed the following equation: ⎛
ω R
⎞
2 2
tex . .
Tout = ⎜ Tp + r ⎟ e μπ / 2
where Tout = the yarn tension outside the rotor, yarn r
Tp = the yarn tension at the peeling off point ⎜⎜ 2 ⎟⎟
(point A in Figure), Texy = the yarn linear density ⎝ ⎠
in tex, 7r = the rotor rotational speed in radians, Rr = the rotor radius, and µ = the coefficient of
⎛ tex .
ω R ⎞
2 2
yarn-rotor surface friction. .
Assuming Tp to be very small, then the equation can be reduced to: T = ⎜ yarn r r ⎟ e μπ / 2
•The above equation indicates that spinning tension in rotor
out
⎜⎜ 2 ⎟⎟
spinning is particularly sensitive to the term (7r² Rr²), which represents ⎝one of the primary⎠ design
criteria of the spinning unit. The importance of yarn tension lies in its significant effect on yarn
quality. Previous studies showed that there is a linear relationship between the variation in yarn
tension and the yarn mass variation (Uster C.V%). The increase in rotor speed or the increase in
rotor diameter results in a consistent reduction in yarn breaking elongation. This effect is attributed
to the increase in yarn tension as a result of the increase in the term (7r² Rr²).
•Increasing the rotor speed was associated with a simultaneous reduction in rotor diameter. The
above equation represents a reasonable justification to this dual trend. In today's technology, the
maximum rotor speed is about 150,000 rpm. This speed is associated with rotor groove diameters of
28 to 30 mm.
•Rotor speed limiting factors: the centrifugal force on the fiber mass inside the rotor, peak yarn
tension, and the bursting stress of the rotor.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Factors Influencing Rotor-Spinning

Performance V

Centrifugal Force on the Fiber Mass Inside the Rotor:

•The centrifugal force (CF) on a fiber mass mf deposited in the rotor groove is given by the following
ω
2
equation: Thus, the increase in rotor speed results in a substantial increase
CF = m f . R f
in the r centrifugal force. The impact of this high centrifugal force is obvious,
more trash and dust deposits in the rotor groove, and consequently, more yarn defects.
•In relation to yarn structure, the centrifugal force is expected to improve the fiber packing in the
yarn. In addition, it is expected to result in a tighter wrapping of the yarn core by the bellybands (Artzt
et al, 1989). As indicated earlier, this effect results in a smaller curling tendency in the yarn. Therefore,
the increase in rotor speed and the simultaneous reduction in rotor diameter may ultimately be limited
by their effects on yarn extensibility. As indicated earlier, yarns with low curling tendency also display
low yarn extensibility by virtue of their "liveliness".

•Peak Tension:
•The Equation suggests that the spinning tension is proportional to the square of the rotor speed, ω .
2

As in case of ring spinning, the tension on the yarn during rotor spinning also exhibits peaks. The
standard deviation of the tension,, σ Ty is proportional to the rotor speed at a power factor of more
ω
>2
than 2 (Stalder, 1993): σ Ty ≈ r
•This means that the increase in rotor speed may result in a rising in tension peaks even sharper than
the average tension does. This effect increases the chance of more end breakage during spinning
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Important Fiber Properties in Rotor-

Spinning I

•From the above discussion, which clearly point

at many of the fiber properties that are important
in rotor spinning. Perhaps, the most important
fiber property is fiber fineness. This is due to the
structural limitations of rotor-spun yarn
discussed earlier, which require more fibers per
yarn cross-section to compensate for the loss of
fiber contribution to yarn strength. For the same
reason, fiber strength is another important
characteristic. Indeed, the introduction of rotor
spinning has greatly shifted the attention to these
two properties.

•With regard to fiber length, rotor spinning has altered the traditional view that ring spinning had
established for many years; that is, fiber length is the most important fiber property. The reason for
this is that long fibers are likely to be more disturbed by turbulent airflow than medium or short
fibers.
•Some early studies revealed that long fibers result in lower rotor-yarn strength compared to that of
ring-spun yarn.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Important Fiber Properties in Rotor-

Spinning II

•They also revealed that the longer

the fiber length, the higher the C.V%
evenness of rotor-spun yarns
compared to that of ring yarns.
However, the key length parameter in
rotor spinning is short fiber content.
A high level of short fibers will result
in low yarn strength and excessive
ends-down.
•In addition to the above fiber
characteristics, rotor spinning has set
new standards for the level of fine
trash and dust in the fiber strand.
This is due to the fact that trash
content is the primary cause of
spinning ends-down. Values of trash
percent of less than 0.2% in the fed
sliver are recommended for rotor
spinning.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Envelopments in Open End Spinning Machines

Rotor spinning was first introduced in ITMA 1967 in Basle.

The first generation of this new technology (the well known
Czech BD 200) proved that spinning was at the threshold of a
new era. A rotor speed of 35,000 rpm was quite stunning
compared to a ring-spinning spindle speed of 10,000 to 12,000
rpm, and a large package size of 1 kg was amazingly larger
than the 120 g ring-spinning bobbin. Since the introduction of
the first generation, developments in rotor spinning have
never ceased. These developments may be divided into three
main directions: (i) design features, (ii) automation, and (iii)
information and control systems. Rieter R 40
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Earlier Developments ITMA 1999

Design Features: Different opening roller is designed with various types of solid clothing suitable for
different types of fibers. B174 and B20 are suitable for cotton, 100% viscose, cotton/viscose blend, and
cotton/acrylic blends. Type S21 is suitable for cotton/polyester blends, polyester/viscose blends, acrylic,
100% good medium staple cotton, and 100% polyester.
•Rotors are designed in different shapes and different dimensions to suite different applications.
•Rotor type T is designed to produce yarn structures resembling ring-spun yarns; it is suitable for
weaving and knitting coarse to medium yarns. Rotor type S is designed for cotton with above-average
trash content, and for all man-made fibers. Rotor type U is designed primarily for coarse-count range,
especially for denim yarns; yarns produced from this type are less liable to curling and less voluminous
compared to the S-rotor. Rotor type G is designed for fine weaving and knitting yarns.
•Rieter offered a rotor of diameter 40 mm, and the RICOFIL rotor, which is specially designed for
combed rotor yarns. Schlafhorst designed navels made from ceramic and chromium-plated steel.
• Special design of the rotor bearing.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Modern Open-End Machines

•The Autocoro 360 is the latest development of Schlafhorst. Up to 360

spinning position and take-up speed up to 300 m/min. Rotor speed up
to 150.000 rpm. Autocoro is able to use rectangular as well as circular
cans.
•The R40 from Rieter runs also at 150.000 rpm. Delivery speed up to
235 m/min, machine length up to 320 rotors.
•Up to 4 Coromat is used for doffing. The piecing made by Coromat
have a strength over 90%. High dynamic drives for sliver intake and
yarn take-up ensures high accuracy of piecing process. Proper laying
of the yarn onto the package is controlled through the acceleration
phase of rotor, which reduces the risk of parallel yarn layers forming
on package.
•Rieter offers integrated automation system. All important functions
rotor cleaning, piecing, package change are combined in one robot. A
UNIfeed tube-supply system, the robot is supplied with empty tubes
before each package change.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Automatic Piecing

Laser light barrier of Quality assurance with

Corbox of Schlafhorst Piecing tester
The Rieter SYNCRO TOP piecing principle, with high piecing speeds and
precisely controlled piecing process guarantees invisible piecing of high strength
that can meet most exact demands in downstream processing. Efficient rotor
cleaning due to removing of trashes and adhered fiber fragments. The robot
prepares the end of sliver in a special way and then feeds it accurately into the
opening unit.
Sclafhorst uses laser technology for measuring with the pin-point precision. A
laser light barrier using for its function the latest diode technology measures the
rotor speed in the rotor acceleration phase. All sequences of the piecing cycle from
braking of the rotor to standstill to transfer of the yarn to the winding unit are
time controlled with precision. Prior to piecing, the yarn subjected to additional
combing and paralleling of the fibers, for better strength
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Drive Mechanism

SDSI Indvidual Motor Controlled Sliver intake due to using the

Stream Line Adapter of Sclafhorst. Yarns of natural fibers,
smooth or structured yarns or yarns with 20 fold to 450 fold
draft, the corbox SE 12 with its individual motor motor
controlled Single Drive Sliver Intake SDSI satisfies all kinds of
demands and applications.
Stepper motor in each spibox guarantees an extra defined sliver
Individual motor drive sliver
intake which is crucial to the production of fancy yarns. The
feed COROBOX SE 12
opening roll speed as well as the yarn draft and twist level can be
set and are infinitely adjustable at the Informator and can be
easily optimized while spinning on the machine running. The
suction system of the machine electronically controlled by the
EVA Electronic Vacuum Adjustment system, guarantees
sustained uniformaty and consistency of vacuum level.
The Rieter SC-Rbox is opened feed-drive gear remains engaged
so the that the risk of damage associated with decouple drive is
eliminated.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Rotor Drive Bearing

The Magnetic Rotor Positioning System of

Autocoro 360 offers the following
advantages:
•Saves Energy, ensures clean
surroundings of the spinbox, prolong
service life time of the spinning
components and driving belts, requires no
readjustment and does not get soiled.
•Maintenance intervals extended 2 to
times.
•Carbon free reinforced rotor brake .
•No oil or grease and no compressed air
needed (saves 24.000 Kw annually) The Magnetic rotor bearing of Autocoro 360

•Reduced spare parts requirements.

 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Winding

Exact unwinding
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Spinning components

Opening rollers
•
mm
Constructed as a solid ring of 64

diameter for cotton and man made

fibers,
for economical replacement
• Optimized tooth shapes for opening
fibers
without damage
• High wear resistance for long life-
time
• Open arrangement of the opening
rollers
prevents clogging in the region of the
cover.
Rotors
• Steel rotors of diameter 28 mm to 56
mm
for all rotor-yarn applications
• Highly effective wear resistance for
long Draw-off nozzles
life-time and constant yarn quality • Made from high-quality ceramics for a wide
• Special designs for particular types of range of yarn structures. Magnetic holder
yarn for replacement without tools
• Easily removable channel inserts for • Nozzles with special ceramic inserts for
rapid knitting yarns similar to ring-spun yarns
adjustment to the rotor diameter, • Ceramic nozzles for protective processing
optionally with SPEEDpass. of man made fibers and blends at high rotor
speeds
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Monitoring and Controlling

• High flexibility is attained through

VARIOdraft, i.e. infinitely variable
adjustment
of draft, twist, winding tension, as
well
as rotor speed and, optionally,
opening roller
speed. Settings are carried out at the
machine’s control panel, using
Touch-
Screen technology. • A user-friendly control panel
allows
• The centrally adjustable package retrieval of detailed information on
each
density
spinning position and also rapid and
allows fast changeovers to soft dye simple
cones input of adjustments at any time.
• Central monitoring of all production
or to compact weaving-yarn and
packages. quality data is possible by connection
to
• The spinning elements of the new Rieter’s SPIDERweb* central data
SC-R collection
system.
spinning unit can be easily exchanged.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Monitoring and Controlling (Plant Operation)

 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Monitoring and Controlling (Corolab Plus)

Schlafhorst utilizes the COROLAB PLUS® system which detects yarn faults
using an optical system. As shown in the figure, a transmitter sends a beam
of light through the measuring field to the receiver. This light beam is
partially interrupted by the yarn, which is to be measured and which runs
through the measuring field during spinning. Simultaneously, a second light
beam sent out by the transmitter falls upon a reference receiver. The
amounts of light, which are transmitted in each case, are compared. If the
measuring field is empty both amounts are equal. The yarn in the measuring
field throws a shadow onto the receiver, whilst the reference receiver always
retains 100% of the light. From the difference in values COROLAB®
measures yarn diameter with an accuracy of one hundredth of a millimeter.
At the start of the operation, COROLAB® determines the diameter mean
value of the yarn at each spinning unit over the first few yarn meters. It uses
the mean diameter as a control reference value. During spinning, any unit
producing a yarn diameter deviating from the reference value is detected
and stopped. Information provided by this system includes: classified yarn
faults, gradually increasing long thick and thin places, yarn irregularity,
spectrograms, and variance-length analysis. In addition, the system is
capable of detecting “moiré”, which is a periodic yarn fault caused by
partial contamination in the rotor. The distance between the faults is a
minimum one-rotor circumference. Accordingly, moire detection is
controlled by the diameter deviation in percent and by the rotor
circumference. The system permits detection of moire within as little as 2
meters of yarn
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Core Open-End Spun Yarns (Rotona)

The filament entered to the rotor through

the shaft. The fibers forming the Open end
yarn wraps around the filament, which
has no twist.
It is also important to keep the tension at a
constant value. The yarn produced can be
compared with the classical ring spun core
spun yarns.
The production speed is up to seven times
as ring spinning.
Better elasticity of yarns
The counts produced Ne. 5- 30
The yarns can be used in sport wears and
in rubber industry.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Air-Jet Spinning

The classical air-jet spinning uses the principle of false-

twisting to produce a yarn of uniquely different structure
from that of ring or rotor spun yarn. While ring-spinning is
characterized by a continuity in the fiber flow, and rotor
spinning is characterized by a complete separation of fibers
prior to spinning, air-jet spinning exhibits an intermediate
feature in which part of the fiber strand flows continuously
and another part is separated.
Similar to rotor spinning, the input strand in air-jet spinning
is a drawn sliver, which may be carded or combed. Drafting
is achieved using multiple zone roller drafting. The
consolidation mechanism in air-jet spinning is achieved by
blowing out compressed air through air nozzle holes of about
0.4mm diameter to form an air vortex. The air revolves at
high speed (more than 3 million rpm). Thus, the rotating
element in air-jet spinning is air. This results in a rotation of
the fiber bundle at a rate typically ranging from 200,000 to
300,000 rpm.
The figures shows the air-jet spinning system produced by
Murata. Two air nozzles are used: nozzle 1 may be called the
"end-opening" nozzle, and nozzle 2 may be called "the
twisting nozzle". These names imply the specific functions of
these two nozzles as explained below
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

The Principle of Air-Jet Spinning

To simplify the principle of the consolidation mechanism,

suppose that only nozzle 2 is at work and that air is rotating
in a clockwise direction. This action will result in twisting
the fibers fed to the nozzle to form a yarn. When the yarn
leaves the nozzle, untwisting takes place. Thus, with one air
nozzle, a case of pure false twisting is achieved. In the actual
machine, another nozzle (nozzle 1) is positioned between the
nip of the front roller and nozzle 2, with air rotating in a
counterclockwise direction. Thus, the two nozzles apply air
rotation in two opposite directions. However, the air in
nozzle 2 has a higher rotational speed than nozzle 1 to avoid
complete false twisting. The fiber strand, coming out of the
delivery roll, forms a spinning triangle similar to that in
ring spinning. However, fibers in this triangle are under
much less tension than those in ring spinning. In other
words, the fibers in the triangle are comparatively loose.
The air rotation of the fiber strand in the two nozzles results
in ballooning the fiber bundle between the front roller and
nozzle 1, and in turning the balloon in nozzle 2. This balloon
has no significant tension, which results in some fibers being
raised from the bundle surface and move freely. This
process is called "the end-opening" action. Thus, the
opposite rotation of air in nozzle 1 assists in detaching some
fibers from the input strand
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Main Parameters affecting Air Jet Spinning

The main spinning parameters in air-jet

spinning are as follows :
• The main draft ratio (VFront
Roller/VSecond or Apron roller); this varies from
15 to 50, but generally runs from 30 to
40.
•Distance between the first nozzle and the
nip of the front roller, k.
•The feed ratio ((VFront Roller/VDelivery); this
ranges from 0.98 to 0.99
•Spinning speed (up to 300 m/min)
•Air pressure in nozzle 1 (typically, 2-5
kgf/cm²)
•Air pressure in nozzle 2 (typically, 2-5
kgf/cm²)
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Effect of Spinning Parameters on Yarn Structure

Many investigators examined the structure

of air-jet spun yarns (e.g. Grosberg et al,
1987, Lawrence et al, 1991, Nakahara, 1984
and 1986, Chasmawala et al, 1990, Krause et
al 1990, and El Mogahzy, 1994). Using an
air-jet experimental unit, Lawrence divided
air-jet yarn structures into three main
classes:
•Class I: a twistless core, which at times is
crimped, but wrapped uniformly by a thin
fiber ribbon with a uniform helix angle (40-
45o)
•Class II: a twistless core randomly wrapped
by fibers, in a singular state and in groups,
showing Z and S directions of wrap with
differing helix angles (45-90o). Core crimp is
not as pronounced as in Class I.
•Class III: unwrapped sections of yarn core,
at times having residual twist
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Developments in Air-Jet Spinning

Air-jet spinning machinery may be

divided into two main types: single end
spinners, and twin spinners
In the twin-spinner, two slivers are fed to
the same drafting system where they are
drafted. The drafted strands are then fed
to two different spinning units (air
nozzles) to produce two single yarns.
These two yarns are then doubled
together onto a take-up package suitable
for two-for-one twisting system. The twin
spinner is therefore suitable for
applications where plied yarns are
required. In comparison with ring
spinning, the twin spinner eliminates
roving, winding, and doubling
machinery.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Murata Vortex Spinning (MVS)

The Murata Vortex Spinning (MVS) system was introduced in

1998 under the commercial name “MVS851”. This system uses
the principle of air vortex to produce a yarn similar in structure
to that of the ring-spun yarn. The idea of this development is to
improve two important features of the jet-spinning system: (i) the
number of wrapper fibers, and (ii) the length of wrapper fibers.
Accordingly, MVS should be considered as an inevitable and
natural evolution of the MJS system. The driving force of MVS
development was to produce 100% cotton yarns on jet spinning .
As in the conventional MJS, a finished drawn sliver is directly fed
to a roller drafting system, similar to that used on the MJS
system. The drafted fibers are passed through an air-jet nozzle
and hollow spindle. Fibers exiting the nip of the front rollers are
sucked into a spiral orifice at the entrance of the air nozzle, and
they are then held together more firmly as they move towards the
tip of a needle protruding from the orifice. At this stage, the force
of the air stream twists the fibers. This twisting motion tends to
flow upwards. The needle protruding from the orifice prevents
this upward propagation (twist penetration). Therefore, the
upper portions of some fibers are separated from the nip point of
the front rollers but they are kept open.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Murata Vortex Spinning (MVS)

After the fibers have passed through the orifice, the upper portions of
the fibers begin to expand due to the whirling force of the jet air
stream and they twine over the hollow spindle. The fibers twined over
the spindle are whirled around the fiber core and made into MVS
yarn as they are drawn into the hollow spindle. The finished yarn is
wound onto a package after it is cleared using defect detector. Thus,
the consolidation of fibers is achieved by applying a rapidly spiraling
flow of compressed air at a non-rotating spindle tip in the air nozzle.
One of the spinning parameters that influence the physical
characteristics of MVS yarn is the distance between the nip of the
front roller and the tip of the spindle (distance L in Figure 9.35). The
larger this distance is, the more the “upper portion open” fibers,
resulting in a yarn of characteristics similar to those of truly twisted
yarns. If the distance is too large, the waste fiber rate will also be
extremely large. Murata suggests a distance that is slightly
shorter than the average length of fibers.
Another important feature of MVS, which was inherited from the other MJS systems, is the
balanced strength/count effect. Coarse yarns exhibit better packing, and more parallel core fibers.
Fine yarns exhibit larger number of fiber wrappers. This effect results in approximately the same
count-strength product for both fine and coarse yarns. In case of MVS, the finer the yarn count, the
closer the yarn strength is to that of ring-spun yarn
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Production of Different Yarns

As shown in Figure 9.32, both MJS 802 and

MTS 881 utilize a 4/4 drafting system with
double apron. MJS 802 H utilizes a 5/5 drafting
system. The 5/5 drafting system is believed to
have a better control on the sliver through a
gradual zonal draft. It enables high draft
spinning of up to 300. According to Murata, this
results in about 33% increase in the production
rate (kg/hr) and up to 50% increase in spinning
speed (m/min.). In this regard, we should point
out that the spinning speed in air-jet spinning
depends largely on the yarn count to be
produced
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Special Core Yarn

Specialty yarns may be made from

continuous filaments (e.g. polyester) in the
core surrounded with a wrapper of cotton
staple fibers. It can also be made from fibers
of different colors to produce special effects.
Murata designed a number of systems that
are suitable for producing such type of
yarns. For example, the SPUNDEX® core
yarn device permits drawing of elastic
polyurethane fibers 4 to 6 times using
positive feed rollers and winding short fibers
(e.g. 100% cotton) around the core as the
sheath. In this system the two types of fibers
follow two different pathways before they
are entered together to the nip of the front
roller.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Friction Spinning (Dref 2)

This system can use a wide range of raw material from

reclaimed waste fibers to high-tech specialty fibers and
from natural staple fibers to man-made continuous
filaments. The end products that can be made from
friction-spun yarns are numerous. These include
cleaning rags, mops, secondary carpet backing for tufted
carpets, asbestos substitutes for friction linings, packing,
gaskets, upholstery, recycled fibers outerwear, high-
tenacity fire resistant protective clothing, and
composites for the aviation, and automotive components.
In DREF 2, a card or drawn sliver is fed to an opening
roller (or a carding drum) for individualization or
separation of fibers. An air current carries the fibers
from the card drum to the nip of the friction drums,
where the fibers are twisted together to form a yarn.
Take-up rollers pull the yarn out of the twisting zone to
the winding unit. DREF 2 can handle a wide range of
raw material including natural, man-made, recycled,
blended or industrial (aramids, glass and carbon) fibers
. The total feed weight can be as high as 30 ktex or 420 grains/yd. For example, 6 slivers each of 70 grains/yd can be fed to
the carding unit to produce a yarn. The fiber fineness may range from 1.7 to 17 dtex (1.5-15 denier). Staple length may
vary from 0.8 to 6 inch. Feeding, say, a filament as a core through a special core-feeding system and using the fibers
coming out of the opening roll as a sheath can produce a core/sheath yarn. The yarn produced on DREF2 is on the coarse
side with a typical range from 0.15's to 6's (4000 -100 tex). The delivery speed may reach up to 300 m/min depending on
fiber type and yarn count.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Friction Spinning (Dref 3)

DREF 3 has the same flexibility of the DREF 2 in handling

a wide range of raw material. The core fiber from the first
drafting unit can be almost any synthetic fiber including
industrial fibers (e.g. aramid and carbon); these fibers can
be pure or blended. Cotton can be used if it is blended with
synthetic fiber. The second drafting unit uses the same
fibers with the addition that it can use carded cotton sliver.
Filaments that can be used include metallic wire, glass
filament, elastomeric filament, monofilament, textured
filament, and high tenacity filament. The sliver weight
range for the drafting units is 2.5-3.5 ktex (35-50 gr/yd) for
each sliver. The fiber fineness may range from 0.6 to 6.7
dtex (0.5-6.0 denier). The staple length is limited to 1.25-2.5
inch. DREF 3 can produce yarns in a count range from
0.18's to 18's (667-33 tex). The delivery speed may reach up
to 300 m/min depending on fiber type and yarn count.
As in the conventional MJS, a finished drawn sliver is directly fed to a roller drafting system, similar to that used on the MJS system.
The drafted fibers are passed through an air-jet nozzle and hollow spindle. Fibers exiting the nip of the front rollers are sucked into
a spiral orifice at the entrance of the air nozzle, and they are then held together more firmly as they move towards the tip of a needle
protruding from the orifice. At this stage, the force of the air stream twists the fibers. This twisting motion tends to flow upwards.
The needle protruding from the orifice prevents this upward propagation (twist penetration). Therefore, the upper portions of some
fibers are separated from the nip point of the front rollers but they are kept open. After the fibers have passed through the orifice,
the upper portions of the fibers begin to expand due to the whirling force of the jet air stream and they twine over the hollow
spindle. The fibers twined over the spindle are whirled around the fiber core and made into MVS yarn as they are drawn into the
hollow spindle. The finished yarn is wound onto a package after it is cleared using defect detector. Thus, the consolidation of fibers is
achieved by applying a rapidly spiraling flow of compressed air at a non-rotating spindle tip in the air nozzle
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Yarn Forming (Fiber Landing)

The way fibers are deposited or landed on the friction

drum largely determines the structure of friction spun
yarns. Fiber landing on the friction drum (the
consolidation unit) is quite different from fiber landing
onto the rotor in rotor spinning. This difference is
illustrated in Figure 9.39. Both systems use an air duct
to transfer the fibers from the mechanical drafting unit
(opening roll) to the spinning unit. However, the landing
pattern is substantially different. In rotor spinning,
individual fibers flowing through the air duct are
accelerated as they approach the rotor. The level of twist
(the rotational speed of the rotor) and the spinning
tension positively control the ratio between the number
of fibers per yarn cross-section and the number of fibers
approaching the rotor. The doubling effect resulting
from the fiber condensation in the rotor inside surface,
and the existence of centrifugal force on the fiber mass
assists in improving both the uniformity and the fiber
packing in the yarn.

In friction spinning, fibers coming from the opening unit approach the spinning unit at a higher speed than the outlet
speed of the yarn. This results in a compressive action as the fibers touch the nip between the friction drums. This
compressive action results in a great deal of fiber disorientation or fiber looping.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Twisting Mechanism

As indicated earlier, the twisting

mechanism in friction spinning is
achieved by feeding the fibers into the
nip of two spinning (friction) drums,
which rotate them to form the yarn.
The resulting twist, however, does not
correspond to the ratio of yarn
diameter to drum diameter because of
the slippage effect, which can lead to a
loss of up to 60%. The problem
associated with fiber landing discussed
above adds to the problem of twist loss
by introducing a great deal of twist
variability.
In the absence of a significant spinning tension during twisting, it becomes critically important to
control the fibers as they are rotated in the twisting zone. This control is achieved by applying equal
frictional forces on the two contact areas between the fibers and the spinning drums. The yarn/drum
friction force is determined by the classical Amontons law, F = µN, in which µ is the coefficient of
friction between the fiber surface and the drum surface, and N is the normal force applied on the area
of yarn/drum contact. The normal force is exerted by the air evacuation, which results in fastening the
fibers to the drum surface during twisting. The use of two friction drums allows equal normal force
application on the two contact areas. In addition, the friction coefficients of the two friction drums
should be of equal values.
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Advantages of Dref
 Educational course for Frame Textile Group South Africa, Liberec September 2006
Sayed Ibrahim, TU Liberec, Dept. of Textile Technology – System Identification

Monitoring and Controlling