Created by:

Shakil parvej B.sc in textile engineering Daffodil international university Cell No- 01814777778

Ring Spinning
The Ring Spinning is the most widely used form of spinning machine due to significant advantages in comparison with the new spinning processes. The ring spinning machine is used in the textile industry to simultaneously twist staple fibres into yarn and then wind it onto bobbins for storage. The yarn loop rotating rapidly about a fixed axis generates a surface referred to as "balloon". Ring frame settings are chosen to reduce yarn hairiness and the risk of glazing or melting the fibre.

What is Ring Spinning?

Ring Spinning is the oldest of the present day spinning processes. Fiber material is supplied to the ring-spinning machine in the form of roving. The fiber mass of the roving is reduced by a drafting unit. The twist inserted moves backwards and reaches the fibers leaving the drafting unit. The fibers lay around one another in concentric helical paths. The normal forces encountered by the fibers enhance

the adhesive forces between the fibers and prevent fibers from flying or slipping past each other under the tensile strain. It is the process of further drawing out roving to the final yarn count needed, inserting twist to the fibres by means of a rotating spindle and winding the yarn on a bobbin. These three stages take place simultaneously and continuously. A mechanically driven spindle, on which the yarn package firmly sits, is responsible for twist. A stationary ring is around the spindle, which holds the traveler. Yarn from the drafting unit is drawn under the traveler, and then led to the yarn package. In order to wind the twisted yarn on a bobbin tube carried by the spindle, the traveler is required to cooperate with the spindle. The traveler moves on the ring without any physical drive, but is carried along by the yarn it is threaded with. The rotation rate of traveler is lower than the spindle, and this difference in the speeds of traveler and the spindle enables the winding of the yarn on the tube. A controlled up and down movement of the ring determines the shape of the yarn package, called Cop or Bobbin. Ring spinning technology provides the widest range in terms of the yarn counts it can produce. Ring spinning is a comparatively expensive process because of its slower production speeds and the additional processes (roving and winding) required for producing ring spun yarns. Ring spun yarns produce high quality and are mainly produced in the fine (60 Ne, 10 tex) to medium count (30 Ne, 20 tex) range, with a small amount produced in the coarse count (10 Ne, 60 tex) range. End uses include high quality underwear, shirting, towels.The fibers in the ring yarn are highly parallel and helical in nature, and the fiber arrangement is uniform along the thickness of the yarn. The yarn has a compact structure, with essentially no wrapper or hooked fibers. The self-locked structure is the result of intensive fiber migration, which in turn is influenced by the triangular geometry of the spinning zone and the high spinning tensions. The high axial strength of the yarn is the result of unique self-locked structure.

Process line of Ring Spinning

Ring Spinning Schematics

Arrangements in Ring Spinning

Drafting arrangement It is the most important part of the machine.It mainly influences eveness and strength.All modern Ring Spinning machines are fitted with 3/3 double-apron drafting arrangements. 1. Drive is applied to the lower fluted steel rollers 2. Top rollers are carried in pivoted weighting arms. Top rollers are arranged over fluted rollers and pressed against them. 3. As the drafted strands contains few fibers in the main drafing field, aprons are used to guide the fibers

Drafting Limits
Fiber type Carded cotton Carded Blend Combed Cotton and Blended yarns Drafting Limit >=35 >=40 Medium fineness >=40

Synthetic Fibers Spindle arrangement

Fine yarns>=45 >=50

The spindle arrangement consists of the following parts 4. Tread guide 5. Balloon control ring 6. Ring 7. Spindle 8. Bear 9. Ring Rail 10. Bolster 11. Nut The spindle consists of two clearly seperate parts namely the upper part and the bolster part.The upper part is made of aluminium alloy and is slightly tapered.Near its upper ends and innlarger spindles, also near the lower end, it has a tube gripping device that ensures firm seating of th tube on the upper part. Mechanically the spindle is capable of speedsd upto 28000 rev/min.This maximum speed cannot be exploited comercially because the traveler speed is limited.The centering of the spindles relative to the rings should be as accurate as possible. Basically there are types of spindle drives: 12. Tape drive

13. Tangential belt drive

14. Ring and Traveler arrangement Basic forms of rings can be classified into

Lubricated rings(in woollen and worsted spinning unlubricated rins (in short staple spinning) It is the standard ring of the short staple spinning mills. It can be of two types 1.Single sided rings 2. Double sided rings. For rings used in short staple spinning milltwo dimensions are of prime importance 1.internal diameter and 2. the Flange width

Materials for Ring and Traveler Required properties for Ring materials o o o The ring should always be hard and tough on its exteriors The traveler hardness should be lower so that wear occurs mainly on travelers,which is easier and cheaper to replace Surface smoothness is also important

The traveler o o o o

The traveler imparts twist to the yarn It enables winding of the yarn on the cop Its speed is somewhat less than that of a spindle The traveler does not have a drive of its own but is dragged along behind

the spindle

The traveler mass The traveler mass determines the winding and the balloon tension.If the traeler is too small the balloon will be too big and the cop too soft, material take-up in the cop will be too low.An unduly high traveler mass leads to high yarn tensions and many end breaks

Ring Spinning Process

Roving bobbins are creeled in appopriate holders Guide rods leave the roving into the drafting arrangements Drafting arrangements attenuate the roving to the final count The drafting arangenments is inclined at an angle of 45 degrees to 60 degrees. Upon leaving the front rollers the fibre strand is twisted to impart strength Each rotation of th e spindle imparts one twist to the strand The twist is generated by the spindle which is rotating at high speed The directions of the twist is either "S" or "Z" This completes the spinning of the yarn The amount of twist inserted in the yarn is controlled by the front roll or the delivery speed and traveler rational speed

In practice, spindle speed(n spindle) is used instead of traveler speed in the above equation, the spindle speed is slightly higher than traveler speed Yarn Winding is performed simulatenously with Twisting

The difference in the speed beween traveler and spindle causes the yarn to wind on the package The size of the yarn pckage is limited by the ring diameter, which has to be small to increase the spindle rotation at the same traveler speed

Drafts, Twists and Winding Speed

The draft is the ration between the delivery speed and the feeding speed. The twist is the ratio between spindle speed and the delivery speed Winding speed is directly proportional to delivery speed Contraction occurs in yarn by increasing twists

Traveler speed/Linear Relationship

The twist is given by

The traveler speed can be approximated to spindle speed in the above equation Increase in productivity will be through an increase in traveler speed

(1) A weighting arm (2) presses three top rollers (3) on to three bottom cylinders (4) which rotate at different speeds. The first bottom cylinder and top roller rotate very slowly, the middle ones move 10 to 20% faster and the front bottom cylinder and top roller about 12 to 30 times faster, depending on the fibre material. Because of these different speeds and the loads on the top rollers, the raw material, (5) which is fed into the drafting system, is drawn, and in case the thread becomes about 12 to 30 times thinner.The top rollers are coated with rubber cots to improve the clamping effect. Between the middle and the front roller, the fibre mass is guided between two small rubber belts (6) the top and bottom aprons. The top apron is tensioned and guided by a top apron cradle (7). Smooth and constant running of the aprons is very important to yarn quality.While leaving the last top roller and bottom cylinder of the drafting system, the fibre mass is given a twist by a metal ring (8) with a rotating traveller (9) and a rotating spindle (10), which are located underneath the drafting system. The metal ring is the origin for the name of the ring spinning machine. The twist creates friction between the fibres by which the strength of the fibre mass increases. In this state, the fibre mass is now called yarn. The yarn is wound on to a bobbin attached to the spindle. The speed of the spindles amounts to 10,000 to 14,000 r/min for wool and about 18,000 to 25,000 r/min for cotton. Thus one metre of yarn contains between 300 and 2,000 twists. The weighting arm is required to allow different loads to be set on the top rollers. Normally this is achieved by helical springs which can be adjusted mechanically in steps. Also the distances between the rollers have to be adjustable. The distance has to be larger than the length of the longest fibres to avoid the situation where single fibres are torn between the clamping points of top rollers and bottom cylinders.

Basic Principles of Ring Spinning

Some of the basic principles of Ring Spinning are as follows:1. Drafting Mechanism To attenuate roving until the desired fineness is reached.

2. Consolidation(strength) Mechanism To impart strength to the fiber by twisting it.

3. Winding and Package forming Mechanism To wind up the resulting yarn in a package suitable for storage, transportaion and further processing.

Ring-frame

The ring spinning frame, commonly called the ring, is the conventional spinning system and it transforms the roving from the roving frame into spun yarn using the operations of:

->Drawing ->Twisting ->Winding

In the last step of yarn production, the staple fibers are fed to the ring spinning frame, after passing through the blow room (opening and cleaning) and the carding frame, drawing frame and flyer (separation of individual fibers, parallelization, formation of a fiber tape). Here, the finished yarn is produced by drawing and rotating operations.

Some of the Operation involved in ring frame

1. Creel in 2. Drafting 3. Twisting 4. Laying out

5. Building 6. Doffing 7. Winding

Objectives of Ring Spinning

Following are the core objectives of ring spinning : 1. To draft the roving fed to the ring spinning frame i,e to convert roving into very fine strand called yarn.

2. To impart strength to the yarn by inserting the necessary amount of twist.

3. To collect twisted strand called yarn onto handy and transportable package by winding the twisted thread on a cylindrical bobbin or tube.

How Ring Spinning effects the quality of the yarn?

Ring spinning is the first stage of post spinning in which yarn produced from the roving installed on the hanger on the ring machine. Ring process is the heart of textile plant and there is lot of factors which has an effect on the yarn quality.

Speed of machine makes a major role on the yarn quality, as the speed increase of ring machine, the imperfection (Neps 200%, Thick +50, Thin -50) of yarn increase. Hairiness is also affected in ring production process and mainly produced by the movement of burnt traveler and high speed of machine. CV of count is also very important and ring spinning process is the last stage of process where we can reduce the CV of yarn count. Imperfection of yarn count from quality point of view is so important that every customer required this quality standard, that imperfection should be as minimum as possible. Ring spinning process also effects on twist variation during manufacturing of yarn. It causes major problems during working in the next process

Problems in Ring Spinning

Ring spinning process is a very critical process in the whole plant and it has also the direct relation to production of plant. Its difficult to manage it and lot of problems occurs during process. Following are some production, mechanical and electric problems here.

Most of operators dont know about how to handle the machine. Due to lack of training of employees, they can create problems when they work in the department like problems of material handling, wrong traveler and bobbin color. Ends down is the major problems in ring machine and it cause an efficiency and production loss. Due to lack of training of maintenance staff, mechanical fault is creating a problem and loss of mechanical parts, efficiency and production of plant. Improper maintenance is also creating problems related to maintenance and electric fault during running of machine. Electric problems are also occurred due to lack of electric staff and they are unable to take corrective and preventive action against any fault. Some faults are occurred due to manufacturer of machine like software problem,communication problem and load capacity problems.

Success Factors in Ring Spinning

In ring spinning process, there are some critical success factors which directly effect on yarn quality and profitability of the plant.

Strength of Yarn If there is need to reduce the defects and improve quality of yarn, strength of yarn is so important that without it we cant take best results in the next process. Strength of yarn depends on twist of yarn, as the twist increases the strength is also increases up to a certain limit.

CV of Yarn From customers point of view, CV of count is very important and its difficult to achieve and maintain in the ring spinning process. CV of yarn is the variation of different parameters like,strength, count etc.

Advantages of Ring Spinning

Following are the advantages of Ring Spinning Process

Production of high strength yarns. Spinning of fine count yarns. Proper for special yarns.

It is universally applicable (any material can be spun). The know how for operation of machine is well established accessible to everyone. It is flexible as regards quantities (blend and lot size). Since the speeds in drawing section are best controlled, yarn evenness is excellent. But if short fibers are too much, yarn unevenness occurs. Fine yarns can be produced as compared to open-end system

Disadvantages of Ring Spinning

Following are the disadvantages of choosing Ring Spinning Process

Process stages are more numerous. Roving stage exists as an extra process compared to the other systems. Yarn breakages are more numerous as a result of ring traveller friction and yarn air friction. Interruptions, broken ends and piecing up problems exist because of the yarn breakages. The high speed of the traveller damages the fibers. The capacity of the cops is limited. Energy cost is very high. Low production rate. New spinning processes have difficulty in gaining widespread acceptance. Owing to their individual limitations, the new spinning processes are confined to restricted sectors of the market. The ring frame can only survive in longer term if further success is achieved in automation of the ring spinning process. Also, spinning costs must be markedly reduced since this machine is significant cost factor in spinning mill. The cost structure in ring spinning mill is shown in the graph.