Abstract
In this paper, we propose a novel method for manufacturing a ring-spun slub yarn through multi-channel drafting using a computer numerically controlled (CNC) ring spinning frame. Through controlling the speeds of the feeding rollers, the apron rollers and the spindle, we can manipulate the blending ratio, linear density and twist of the spun yarn online, offering more degrees of freedom to configure fibers in the spun yarn. Furthermore, we develop a digital control system in conjunction with a CNC ring spinning machine, in which each CNC ring spinning machine serves as a drone machine that receives commands from a central computer. A self-developed management platform is designed to help the client manage these drone machines via online regulation. At last, a series of experiments are conducted to examine the impact of manufacturing parameters on the structures and properties of slub yarn. We found that the descriptive parameters that affect the breaking force of the slub yarn samples are the slub length, slub distance, slub multiplier, and roving ratio. The parameters that affect the breaking elongation are obtained as the slub length, slub distance, slub multiplier, and twist coefficient.
Highlights
The fiber configuration is critical for the properties of composite yarn, such as color appearance
The actual slub lengths are larger and the actual slub distances are smaller than the theoretical values, as shown in Tables 2 and 3 possibly because at the end of each slub production cycle, it took more time to stop the movement of fiber strands held by the nip of the apron rollers due to the inertia of the fibers, which produced longer-than-usual slubs in the slub yarn
The average slub length deviation was obtained as 4.2% at the lower level and 13% at the higher level of the slub distance
Summary
The fiber configuration is critical for the properties of composite yarn, such as color appearance. The manufacturing methods are expected to provide more flexibility to configure the fibers in composite yarns. Ring spinning and rotor spinning are the two most widely used methods for manufacturing yarns. The blending ratio and linear density of the yarn are conventionally fixed in both methods, making them less useful for fabricating color blended spun yarns. Progress has been achieved in rotor spinning and ring spinning by incorporating computer numerically controlled (CNC) systems into spinning machines,[1,2,3] thereby increasing the flexibility of yarn production. Extensive experimental and analytical studies on CNC ring spinning machines, especially regarding the relationship between the manufacturing parameters and the yarn properties, have not been carried out yet
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