Ring Spinning Process Research Articles

Multi-objective Optimization of Yarn Characteristics Using Evolutionary Algorithms: A Comparative Study

In cotton spinning industries, attainment of the most desired yarn characteristics mainly depends on different parameters of the ring or rotor spinning process. Thus, it is often required to determine the optimal parametric settings of a spinning process with the help of some optimization tools. In this paper, two multi-response optimization problems are considered and subsequently solved using four popular evolutionary algorithms, i.e. artificial bee colony algorithm, ant colony optimization algorithm, particle swarm optimization algorithm and non-dominated sorting genetic algorithm-II for searching out the global optimal settings of ring and rotor spinning processes. As the process parameters’ settings derived using single response optimization solutions are often impractical to maintain, it is always recommended to set them based on the results of multi-response optimization techniques. It is observed that among these four algorithms, particle swarm optimization excels over the others with respect to the derived optimal solution, consistency of the solution and convergence speed. The developed scatter diagrams also help in investigating the effects of changing values of different process parameters on various yarn qualities.

A Numerical and Experimental Study on a Pre-Twisted Ring Spinning System.

The ring spinning process is the most widely used method in the spinning industry. Nowadays, the labor cost become more and more expensive, and it is essential to improve productivity. For increasing the productivity, a modification of adding a pre-twister and holding roller on the traditional ring spinning system have been discussed in this paper. The computational fluid dynamics (CFD) are introduced to study the effects of pre-twister and spinning tests are implemented for verification. The numerical simulations show that the cavity conical degree and nozzle numbers of the pre-twister are the key parameters which affect the airflow fluctuation in the cavity, and have obvious effects on the resultant yarn twist. By contrast, the axial angle and tangential angle of the nozzle have less effect on the resultant yarn twist. When the fiber bundles pass by the front nip, they are affected by the vortex and result in a partially strengthened and wrapped structure which could be subsequently twisted less by the traveler and ring, so the productivity could be potentially increased. According to the spinning tests, an evident productivity increase by nearly 30% for medium cotton yarns can be achieved, and the yarns have an acceptable reduction in nearly all properties.

Analysis of yarn properties in the superconducting magnetic bearing-based ring spinning process

The fundamental research work about the superconducting magnetic bearing (SMB) twisting system provides huge potential to eliminate the most important limitation of productivity, that is, the friction in the ring traveler system of the existing ring spinning process. As a continuity of the research work, the functionality of the SMB spinning has been carried out with different angular spindle speeds, yarn counts, and materials in order to determine the influence of the SMB technology. The current paper presents a comparative investigation of the yarn properties, such as yarn tenacity, yarn elongation, yarn evenness, microscopic views, etc., between conventional and SMB ring spun yarn. The intensive analysis confirms that the SMB system enables one to produce satisfactory yarn quality similar to that of conventional ring spun yarn up to 15,000 rpm. The influence of conventional and SMB spinning processes on yarn properties has been further analyzed statistically using an analysis of variance.

Exploratory and predictive logistic modeling of a ring spinning process using historical data

The end breakage rate (EBR), which is one of the most important quality variables used to determine the yield of a spinning process, depends on various process conditions and fiber/yarn properties. In the current study, historical data consisting of more than 10,000 runs from 55 ring spinning machines recorded under normal operation in YUNSA Worsted and Woolen Company in Turkey were analyzed using exploratory and predictive statistical techniques. Principal Component Analysis (PCA) was used to determine subsets of quantitative variables, which vary collectively, forming clusters for different machine types. Correspondence Analysis (CA) was found to be particularly beneficial to determine the association between machines and nominal variables, which make a significant contribution to product quality in textile industries. The current spinning process requires accurate discrimination between acceptable and faulty yarns, determined via a threshold on the EBR, so logistic regression was utilized for the prediction of faulty yarns. The Receiver Operating Characteristic curves showed that the discriminative capacity of the logistic models was at an acceptable level, almost on a par with that of Artificial Neural Network (ANN) models. For different types of machines, while yarn count, roving count, lot size, twist level and composition were commonly present in logistic models, the magnitude of their partial effects varied significantly. In conclusion, PCA, CA and logistic regression are suggested, along with ANN models, to be used for textile industries in online monitoring, detecting faulty machines, choosing optimum machines for specific operational conditions and determining the range of process variables for which controlled experiments may be required.

Research on mechanical properties of fibers at asymmetric ring spinning triangle using Finite Element Method

In the ring spinning process of staple yarn, spinning triangle is a critical zone, whose geometry influences the mechanical properties of fiber in the spinning triangle directly. In the practical spinning, especially in some modified ring spinning systems, the spinning triangle is often asymmetric, in which the horizontal deviation of the twisting point is existed and lead to an obvious angle between the yarn spinning tension and the vertical axis perpendicular to the nip line. Therefore, in this paper, the fiber tension distributions in this kind of asymmetric spinning triangle were studied using the finite element method. In the direct finite element model, the initial strain of fibers in the two sides of spinning triangle is asymmetric, and corresponding accidental fiber tensions would be produced, which makes the fiber move to the middle of the spinning triangle and lead to inaccurate results. Therefore, in the paper, one new finite element model of the asymmetric spinning triangle with left (right) horizontal deviation was presented for calculating the fiber tension. In the model, an asymmetric spinning triangle with the same right (left) horizontal deviation was used to combine with the original asymmetric spinning triangle, and one axisymmetric quadrangle was built, and the symmetry axis is the central fiber. Then, the fiber tension and torque distributions in the spinning triangles of Ne40 (14.6 tex) and Ne60 (9.7 tex) cotton spun yarn were numerical simulated with different horizontal deviations and twist factors. Furthermore, the accuracy of the proposed finite element model in calculating the fiber tensions was validated by comparing it with the theoretical model built by the energy approach.

Measurement Methods of Dynamic Yarn Tension in a Ring Spinning Process

The most common measuring method to characterise the dynamic yarn path in the ring spinning process is to measure the yarn tension, where the yarn path is almost straight. However, it is much more complex to measure the yarn tension at the other positions, for example, between the yarn guide and traveller (balloon zone) and between the traveller and winding point of the cop (winding zone), as the yarn rotates continuously around the spindle axis. In this paper, two new methods of yarn tension measurement in the balloon zone are proposed. In the first method, the balloon shape was first recorded with a high speed camera. The balloon tension was then calculated by comparing the yarn strain (occurring in the balloon zone) measured by a digital image analysis program with the stress-strain curve of the yarn produced. In the second method, the radial forces of the rotating balloon were measured by using modified measurement techniques for measurement of yarn ten sion. Moreover a customised sensor was developed to measure the winding tension between the traveller and cop. The values measured were validated with a theoretical model and a good correlation between the measured and theoretical values could be revealed.

Mathematical modeling of the dynamic yarn path depending on spindle speed in a ring spinning process

This paper presents a mathematical model to predict the distribution of yarn tension and the balloon shape as a function of spindle speed in the ring spinning process. The dynamic yarn path from the delivery rollers to the winding point on the cop has been described with a non-linear differential equation system. These equations have been integrated with a Runge–Kutta method using MATLAB software. Since the numerical solution of the equations strongly depends on initial values, an algorithm of sensitivity analysis has been developed to predict the right choice of initial values in order to find a stable solution. For model validation purposes, the yarn tension has been measured between delivery rollers and yarn guide. Furthermore, a high-speed camera has been used to capture the balloon shape at different spindle angular velocities in order to compare the theoretically determined balloon shape with the one that actually occurs on the machine.

Superconducting Magnetic Bearing as Twist Element in Textile Machines

Superconducting magnetic bearings (SMBs) enable the levitation of a magnet in a stable position over a cooled superconductor without the need for an additional positioning system. These passive bearings are being investigated for applications wherever a stationary levitation or a contact-free rotary or linear motion is desired and cannot be realized by simpler means. Ring spinning is the most widely used technique for the production of short staple yarn in the textile industry. The productivity of the ring-spinning process depends on the rotational speed of the spindle. It is limited by friction in the so-called ring-traveler twist element. During the spinning process, the traveler is dragged along the ring by the yarn with up to 30000 r/min. The resulting friction causes wear of the twist element and melting of synthetic yarn at high spindle speeds due to strong heat generation. Recently, an SMB was implemented as a contact-free twist element in a ring-spinning machine up to 11000 r/min. This prototype SMB consists of a rotating permanent-magnetic (PM) NdFeB ring acting as a yarn-driven traveler and a stationary bulk YBCO ring at 77 K in an open LN <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">2</sub> bath. In this paper, we investigate the bearing properties of this SMB with regard to the special requirements of the ring-spinning process. Dynamics of the spatially vibrating and rotating PM ring are analyzed including the forced vibration due to interaction with the yarn. For the expected yarn forces, the displacement amplitude at the resonance frequency remains below the field-cooling height. In addition, the possibility of realizing higher rotational speeds by mechanically reinforcing the NdFeB ring with a shrunk-on steel shell is discussed.

Research on shape of spinning triangles in the ring spinning system

Ring spinning is the most widely used yarn spinning method at present. Spinning triangle is a critical area in the ring spinning process of staple yarn, in which the geometry influences the distribution of fiber and fiber mechanical properties in the spinning triangle directly, and determines the qualities of spun yarn. Therefore, some new modified ring spinning methods have been appeared gradually by changing the spinning triangle actively. In this paper, the qualities of yarn spun by common ring spinning and two kinds of modified ring spinning were studied by analyzing the shapes of spinning triangle. First, 18.2tex cotton yarns were spun on FA507B ring spinning frame with three different spindle speeds and leading distances of top roller, and corresponding spinning triangles were captured using a high-speed camera system OLYMPUS i-speed3 and one kind of transparent front top roller. Then, the qualities of yarn produced by modified FA507B ring spinning system with four-line rollers compact spinning device and a kind of airflow twisting device were analyzed, respectively. 29.2tex, 14.6tex, 9.7tex yarns, and 18.2tex yarns with three negative pressures 1800, 2200, and 2600 Pa were spun, respectively, and corresponding spinning triangles were captured and analyzed comparatively. It is shown that using compact spinning device, the spinning triangle is reduced greatly, and with the increase in negative pressure, the spinning triangle is reduced gradually. Furthermore, 18.2tex yarns were spun on FA507B ring spinning frame and FA507B ring spinning system modified by a kind of airflow twisting device with airflow pressure 0.1Mpa and 0.05Mpa and two different swirling directions including anticlockwise and clockwise, and corresponding spinning triangles were captured and analyzed. It is shown that for the Z (S) twisting spun yarn, under the effects of the clockwise (anticlockwise) airflow, the spinning triangle can be reduced and benefit for reducing yarn hairiness, while under the effects of the anticlockwise (clockwise) airflow, spinning triangle is more symmetric and benefit for reducing the yarn torque possibly.

Research on fiber tension at asymmetric spinning triangle using the finite-element method

Spinning triangle is a critical zone in the ring spinning process of staple yarn, whose geometry influences the fiber tension distribution in the spinning triangle directly and determines the spun yarn qualities. In ring spinning, the spinning triangle is often asymmetric due to the inclination angle of the spinning tension or the migration of the axis fiber at the front roller nip. Therefore, in this paper, the fiber tension distributions in the asymmetric spinning triangle due to the migration of the axis fiber at the front roller nip were studied using the finite element method (FEM). In the direct finite-element model, the initial strain of the axis fiber is set as zero, and the accidental fiber tensions would be produced due to the asymmetric distributions of the initial strain on fibers in the two sides of the spinning triangle. Then, an effective finite-element model of the asymmetric spinning triangle with right (left) axis fiber migration for calculating the fiber tension is built by composing an asymmetric spinning triangle with a corresponding left (right) axis fiber migration and a symmetric spinning triangle is composed. Then, the fiber tension distributions in the spinning triangles in the Ne40 (14.6 tex) and Ne60 (9.7 tex) cotton spun yarn were numerically simulated with different axis fiber migrations and twist factors. Furthermore, the accuracy of the proposed finite-element model in calculating the fiber tension distribution in the asymmetric spinning triangle was validated by comparing it with the theoretical model built by the energy approach. It is shown that the numerical values of fiber tension distribution between the FEM results and the results with the energy method are in good agreement. Meanwhile, with the increase in the migrations of the axis fiber or the yarn twist, fiber tension in the spinning triangle is increased.

Optimization of ring-spinning process parameters using response surface methodology

Several processes are involved in textile industry for yarn production. Ring spinning is the most versatile machine for producing the spun yarn. It is necessary to optimize the ring-spinning process parameters in order to curtail cost and increase the production rate without affecting the yarn quality. In this study, the effects of spinning process parameters namely, spindle speed, roving twist multiplier (roving TM) and yarn TM are studied and have been optimized using three variable Box–Behnken design of Response Surface Methodology. It is determined that spindle speed of 17,000 rpm with 4.1 TM for yarn and 1.3 TM for roving results are the best optimal responses.

Performance of cotton single yarns and knitted fabrics produced by a 2-step spinning method

A low torque spinning method has been recently developed by integrating the ring spinning process with false twisting techniques. As a result of false twist and true twist, a novel single yarn of low torque and soft handle is generated. Based on the similar spinning principle, this paper proposed a 2-step spinning method, which is composed of twisting-anduntwisting operation and can be considered as a variant of the low torque spinning method. The proposed spinning method separates the false twisting process into twisting and untwisting processes which are combined in one step in the low torque spinning method. In this paper, physical properties of yarns produced by the proposed spinning method were evaluated and compared with the conventional yarns. Influences of various spinning parameters on the properties of 2-step yarns were also examined. Furthermore, a systematic study of the physical properties of the 2-step yarns and resultant fabrics with respect to the conventional and low torque ones was carried out. The experimental results showed that the 2-step yarns exhibit slightly higher tenacity, lower wet snarl and much less hairiness than the conventional yarns, which, however, are inferior to the low torque yarns, particularly the evenness. The fabrics made by the 2-step yarns show the softest handle feeling, best airpermeability and moderate spirality angle with acceptable pilling resistance.

A study on the fabrication and functional properties of PET/rayon staple fiber products with ACC@Ag powders

In this study, the fabrication of nano-silver doped activated coir charcoal particles (ACC@Ag) was proposed using chemical reduction method. Certain amount of ACC@Ag was added into the spinning solution after de-foaming process to fabricate viscose rayon staple fibers using wet spinning method. The 1.25 denier × 38 mm viscose rayon/ACC@Ag staple fibers was then blended with 1.5 denier × 1.5 in. polyester staple fibers to fabricate PET/rayon/ACC@Ag with 50%/50% blending ratio and 30 s and 40 s linear density using ring spinning process. The blended yarns are expected to be used for the fiber products with anti-bacterial, warm retention, odor absorption and anti-static properties. This ring blended yarns were then used as the raw material to fabricate woven fabrics with anti-bacterial and anti-electrostatic properties which comply with JIS and AATCC standards. The influences of woven structures, fabric constitutions on the temperature difference, anti-bacterial, odor absorption and anti-electrostatic properties of woven fabrics were also investigated. Finally, the potential applications of the woven fabrics fabricated will also be proposed and suggested in this study.

Review of distribution of fiber tension at the spinning triangle

In the ring spinning process, the spinning triangle plays an important role in the quality and efficiency of yarn spinning. The distribution of fiber tension at the spinning triangle is important. In this study, models such as energy methods, energy methods using false twist, and finite element method are applied. The model parameters on the distribution of fiber tension in the symmetric and asymmetric spinning triangle with a uniform distribution of single fiber, uniform distribution of fiber types, and distribution buckling fibers in the spinning triangle are analyzed. The results show that there is an increase in the distribution of fiber tension in symmetric spinning triangle. Fibers, depending on their position in the spinning triangle, have different tensions. In single fibers in the twist point, the tension of the fiber bundle is maximum, the fiber tension is less, and the compression force of the fiber bundle is greater. The spinning triangle shape is effective on the distribution of fiber tension.

Analysis of Process and Properties of Stainless Steel Filament Wrapped Yarn Based on Multi-Axial Ring Spinning

A new spinning method was presented to spin three-axial stainless steel filament wrapped yarn by modified ring-spinning, where the stainless steel filament was set as the core yarn and the nylon filament for decoration wrapping the stainless steel filament in the fields of the fabric for Shielding application. A set of process parameters was obtained by the ring spinning frame improvement and spinning process optimization, which realized to spin nylon filament wrapped stainless steel filament yarn. Moreover, the structure, and tensile mechanical properties were measured on the wrapped yarns. The results show that the process can spin stainless steel wire wrapped yarn and acquire the excellent performance of the yarn.

Development on the Multi-Component Blending Yarn of Hemp/ Anti Bacteria Fine Rayon/Micro-Porous Polyester Fiber

The hemp, anti-bacteria fine rayon and micro-porous polyester fiber were select to spin into the multi-component blending yarn by ring spinning process. The performances of these fibers were analysed, the spinning process were presented. The multi-component blending yarn of Hemp/Anti bacteria fine rayon/micro-porous polyester fiber of excellent was spun successfully, and the performance of yarn was examined and discussed.

Investigation of Movable Balloon Controller System on a Ring Spinning Frame

Compared to other spinning system, the ring spinning process has been used to produce higher quality yarns, but with a much lower spinning efficiency, resulted from the relatively high spinning tension that leads to increased yarn breakage rates and makes high power consumption. Thus, depressing yarn tension is essential to change the status. In this paper, we design a movable balloon controller system to reduce yarn tension. The system is automatic, composed of powder switch, touch screen, PLC (Programmable Logic Controller), pulling-thread displacement sensor, controller of step motor, step motor and linear module. PLC, the core of the system, controls the position of the balloon controller by a series of programs. Then yarn tension was tested while spinning with movable balloon control ring, fixed balloon control ring and no balloon control ring, respectively. The result shows that the yarn tension can be depressed indeed by equipping this movable balloon controller system to some extent. Additionally, we find that the number of hairiness of ring spun yarns with this system can be reduced to some extent, while yarn tensile properties are not as sensitive to be worse. It is significant to cut down ends-down rate, improve the quality of ring spun yarns, the spinning efficiency as well as the energy efficiency of ring spinning.

Structure-Property Interrelationship of Denim Yarn Produced Using Ring and Compact Spinning Technology

Ring yarns are increasingly used in Denim fabrics. Fibre arrangement in spun yarn influences the various yarn properties. Spinning triangle in case of compact spinning remains smaller than that of conventional ring spinning process; hence the migration of fibres takes place to different extents in yarns spun using these technologies. As a result with the advent of compact spinning technology overall quality of yarn has improved significantly. In view to study the effect of compacting the fibre batt on fibre migration, denim yarns of count 8Ne and 12Ne have been produced using compaction attachments of pneumatic principle based on Marzoli's Olefil and mechanical magnetic principle based on Rotorcraft's RoCos, on the same spindles of Marzoli ringframe. Fibre migration in terms of mean fibre position, RMS deviation and migration intensity has been determined using tracer fibre technique under CCD camera attached with a computer having image processing software. Experimental results have been analyzed using two way ANOVA with replication technique. It was observed that, migration intensity of normal ring yarns is significantly higher than compact yarns whereas migration intensity of mechanical magnetic compact yarns is significantly higher than that of pneumatic compact yarns. There are no significant changes noted in mean fibre position and RMS deviation. These yarn samples are also evaluated for their various yarn characteristics viz. tensile strength, elongation, unevenness, hairiness, etc to determine the structure- property interrelationship.

Numerical simulation of quasi-stationary ring spinning process linear elastic yarn

This article reports a theoretical investigation on the ring spinning balloon in the textile industry. Theoretical equations incorporating yarn elasticity are obtained, which has been ignored by most previous models. This model differs from the earlier ones in that their choice of yarn was perfectly flexible and inextensible; those used here we presume to be more realistic. Discussions in this paper deal with the significance of various yarn elasticity parameters on varying yarn tension and balloon shape. Some results are given, from which the model seems to be very efficient and reliable in the simulation of the ring spinning process. Restrictions on the applicability of the theory are also pointed out.

A new computer geometric modelling approach of yarn structures for the conventional ring spinning process

A new computer modelling approach for three-dimensional yarn structures produced by the conventional ring spinning system is presented. The concept of virtual locations for modelling yarn cross section is extended. Virtual locations are ring configuration with ellipsoid shapes defined by yarn-twist level in each ring layer. A mathematical model based on migrating helix is developed. Fibre migration is governed by geometric and tension mechanisms. The migration parameters include twisting tension, migration period and amplitude. The initial phase and frequency of migration pattern are used as the parameters of fibre migration. Based on the results obtained from the virtual locations concept and mathematical model of twist, a computer-aided design modelling approach for fibre assemblies is presented for geometric and visual simulation of yarn structures. The fibre paths in each interval between two successive cross sections are approximated by non-uniform rational B-spline curves. The geometric model of each fibre is created by sweeping a closed curve along a centreline path. The new model is validated by using process parameters of spun rayon yarn.