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Newsletter - Volume-13, Issue-3, Aug-2013  

Replies from the readers

What is optimizing cop content in ring frame? Explain how to optimize the cop content with various parameters in ring frame?
Mr.A.Kanthimathinathan, Chief Executive Officer, Winsys Limited, Coimbatore,

A bird’s eye view on optimizing cop content in Ring Frame

The given below are influencing Parameters on cop content and Measures to optimize the same for each the Parameter

1. Ring Diameter: Cop diameter is equal to Ring diameter minus 1.5 to 2 MM. For example, the Cop diameter from a Ring frame having 36 MM Rings with proper spindle to ring centering should be set
between 34 to 34.5 MM.

2. Spindle Taper:  Spindles with two common taper sizes are available in the market. One is 1:40 and another is 1:64. Spindle taper of 1:40 gives more cop content than 1:64

3, Chase Length: Chase length of the cop build should be Ring diameter plus 4 to 6 MM. Even though lower Chase length is preferred for cop content, the unwinding performance is affected with very low
chase length. Depending on the quality of unwinding in Auto coners, we can select the lowest possible Chase length within the range of RD plus 4 to 6 MM

4. Number of Coils Per chase: The total number of coils per Chase should be equal to 0.5*square root of count* chase length in MM. For example for 30s Count with Chase length of 44 MM the number of
coils per chase should be equal to 115 .In LMW  Ring Frames, this is taken into account and optimum winding length is suggested for  a given Yarn Count

5. Cop Bottom build: Ring rail Chase is adjusted at the bottom during cop build to pack more content at Bottom stage of the cop build (semispherical shape)

6. Tube thickness:  Tube thickness plays a role in deciding the cop content. Ring tubes are available from thickness levels of 2.2 MM to 3.8 MM for Ring frames. Studious selection of thickness with right kind
of material can help us to use Tubes with lower thickness and get more cop content.

7. Tube Length:  The tube length should be 20 MM higher than the Spindle lift. If the spindle lift is 170 MM the Tube length should be 190 MM. For Auto doffer Ring Frames another 20 MM has to be added for
gripping by Grippers.

8. Tube length utilization:  Maximum space of the tube should be covered by Cop build and the best results on Cop Content can be achieved if we reduce unutilized space in Tube length to 15 MM (For Auto
doffer Ring frames it will be 35 MM.)

9. Other Parameters which has influence on Cop content:

Traveller Size: Heavier the Traveller size Cop content is more.

Higher the Spindle speed the packing is good leading to increase in Cop content
Higher the RH in department the packing is good, the cop content will be higher
For the same count Compact Counts will have more cop content than in Normal counts
Polyester and PV counts will offer more cop content than equivalent cotton count

10. Optimization of Cop Content in Ring frames:

For the given count optimize Coils per chase based on the given formula
Ideally set the Chase length as Ring diameter plus 4 MM.
Set the ring rail motion at the cop bottom to get ideal semispherical shape
Set the Ratching mechanism for ideal cop diameter i.e. Ring Diameter minus 2 MM
Select the matching Traveller for the count and go for one number higher always and our performance of Ring frames should not be compromised
Select the tube length (X MM) according to Spindle lift and utilize maximum space (X-15 MM) for Cop building
Aim for the highest spindle speeds possible for the particular count and its process parameters based on process proficiency
At the time of deciding Ring Frame/Spindles procurement, choose 1:40 MM taper Spindles and Ring Tubes with lower thickness but having good strength.(ideally 2.4 MM thickness)
Maintain Good RH conditions suitable for Spinning relative to the material –Cotton, Viscose or Polyester

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Mr.N.Subramanian, General Manager., Vindhya Spinning Mills, Sivakasi, Tamilnadu

Optimizing the cop content, with various parameters in Ring frame:

Right selection of
1) Larger Ring diameter to accommodate maximum cop content on the empty cop tube, which is, in turn influenced by
2) Ring frame geometry like Lift, Length, Diameter of the empty cop tube, and also the Balloon length, along with
3) Proper Builder and Winding components like Chase length and Winding length, Ring rail speed, Coils/cm, etc, in combination with
4) Suitable Traveller matching optimizes the cop content in Ring frames.

RING DIA AND RING FRAME GEOMETRY.

Ring serves as a track, upon which the Traveller revolves and helps to guide the yarn, on to the bobbin. During cop building process, spinning tension is related to the ratio of Ring diameter (D) and Tube
diameter - (d) i.e., D/d.

Again if Balloon length is bigger and Bobbin lift is more, we have to go for bigger Ring diameter with Heavier Traveller, to compensate the Spinning tension.
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In order to correlate all the above, for Minimum tension, the following are recommended, based on various references/ studies.
a) Average Diameter of the Ring tube (d): Ring diameter (D)=0.48 to 0.50 MM
b) Diameter of the Ring (D) =Spindle gauge distance(S)-25MM
c) Angle of Yarn pull = 29 to 30 degrees
d) Length of the Ring tube (H) = 5 times the diameter of the Ring
e) Maximum cop diameter = 3 MM lesser than Ring diameter
f) Also, Ring diameter should be kept 2 to 3 MM lesser than Balloon control ring.

COP BUILDING & TRAVELLER PERFORMANCE

During cop building Chase & winding length, Ring rail speed and number of coils/CM should be selected in such a way that maximum cop content is achieved, at the same time, Traveller performance, should
not get affected, due to various Tensional forces like ballooning.

The difference of rotational speeds of the Balloon, Traveller, and the Spindle, allows the yarn, to be wound on to the empty tube.  Traveller does the do job of regulating spinning tension, and spinning tension
should be high enough, to have stable balloon.  Chase length is the distance between top and bottom most position of ring rail in one stroke of the cam movement.

Winding length is the ring rail speed i.e. the yarn delivered (or) length of yarn wound per one chase. In order to achieve the above, keeping the chase length constant, if the yarn delivered per chase-winding
length is increased the ring rail speed will be reduced to accommodate more yarn within the given chase and thereby, the distance between the coils will be reduced and results in compact bobbin. Formation
of compact bobbin increases the diameter at every effective winding on point, which results in reduction of yarn winding tension, which leads for better Traveller performance.

Too higher the chase length - leads to wider winding coils / lesser cop content /lesser Traveller Life.
Too lower the chase length - leads to arrow winding coils/ higher cop content.

RECOMMENDED GUIDELINES FOR BETTER PERFORMANCE.

1) Set chase length at Ring diameter (MM) + 10 to 12%.

2) Chase length and Ring rail speed should be selected in such a way that Winding: Binding coil ratio is maintained as 2 to 2.5 : 1.

THE OTHER SECONDARY FACTORS ARE

a) Breakages rate in spinning, should be as low as possible, to avoid lean cops, say below 3 per 100 spindle hours.
b) Count CV in spinning should be maintained below 1.5 to eliminate spindle variations.
c) Minimum diameter empty cop tubes should be used to accommodate maximum yarn content.

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Mr.Rm.Lakshmanan, Freelance Textile Consultant, Coimbatore, Tamilnadu

Cop content  for  a given ring frame is the single prime source of consuming more energy and that alone may  apportion about 30% of the total power consumption of a ring frame and altogether cop content
and  the spindle power  could be of 50%. “Cop contents” in other words the “Package Size” is impacting the Ring frame production efficiency and doffing boys productivity in a ring frame shed. Also this is
one of the deciding factors of the subsequent Cone winding operational efficiency besides determining the number of knots/splice in a cone package.

It is obvious higher package dictates for higher energy consumption while the smaller package reasoning for lower ring frame, winding shed and Doffing Boys/winders efficiency.  With this context to strike a
balance between these, to meet out  the package size for different count ranges (Say Coarser, Medium and fine yarn number) by working out the economics is mean to say “Optimizing Cop content”. It is
paramount to keep the possible higher spindle speeds (without appreciably affecting the yarn quality characteristics) for the study of economics during the exercise of optimizing the cop content. After the
advent of “Built in doffers” in ring frames, Hi-Tech Autoconers, and auto link to R/F and Autoconers etc Optimum Package size has added significance in the context of energy conservation, say units/kg of
yarn production.

Optimizing the cop content:   In the endeavor of  optimizing the cop content for a given ring frame Ring diameter, Lift, weight and Wharves diameter of spindle, Spindle speeds etc are in key role. Earlier it was
in convention and most widely used ring diameter was 42 MM with 180 MM lift spindles of 1 inch wharves diameter. Lesser ring diameter  below  42 MM with lower lift below  180 MM and wharves diameter
of spindles lesser than 1 inch  consolidates twin benefit of impressive power savings and  higher spindle speeds for  optimum cop content. Higher spindle speed is possible in lesser diameter  rings in view of
the reduction in tension acting on the yarn balloon and the resultant cop content with lower lift/weight of spindle  offers the reduction in power consumption in four components of ring frame power Vis-à-vis
Spindle power, Spinning power, package power and empty ring tubes.

In-depth and extensive very earlier research  study evince  10%  higher production/spindle  with 10% or more lower ukg for optimum package size for a given level of yarn quality. Also it concludes the
optimum package size based on overall cost is 7 inches x 38 mm for 34s, 6 inches x 38 mm for 4os, 5”/6” x 38 mm for 60s  for the then prevailed energy and wage cost. 

 It should be ensured that a nominal clearance have to be left between the cop and rings for obstruction free gliding of Travellers over the rings and optimum Traveller weight have to be in top priority as
heavier number Travellers could affect the RKM and breaking elongation percentage of yarn. Concentric spindles and in wobbled running of spindles are the basic needs for optimum cop content.

Synopsis: After the advent of automation no longer higher cop content are worthwhile in the sense of power saving and needs optimization for which ring diameter, Lift, weight and wharves diameter of
spindles with possible relative high spindle speeds are the key parameters to decide and achieve the same and nominal clearance between cop and rings, nominal Traveller weight and the in wobbled and
concentric spindles are the basic needs for optimum cop content. It seems it is ideal to have 180 mm x 40 mm for medium and 170mm x 38 mm for finer and 160mm x 36 mm combinations for very fine yarn
numbers.

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Mr.S Srinivasa Rao, Senior Manager – Maintenance, Sree Akkamamba Textiles Ltd, Tanuku, Andra Pradesh

Optimizing cop content in ring frame means achieving good quantity of cop content with less ends breakage in ring frame and problem free unwinding at next process i.e. cone winding.

To optimize the cop content in ring frame, the following parameters are to be set right.

01. Concentric position of ring, anti balloon ring and   lappet hook with respect to spindle.
02. Smooth movement of ring rail.
03. Correct setting between Traveller clearer and Traveller i.e. 0.2   to 0.3 MM
04. Ideal ratio of ring and tube diameter i.e. 2:1
05. Favorable ratio of tube length and ring i.e. 5:1
06. Distance between top of the tube to thread guide (lappet) to be maintained 1.5 to 2 x tube diameter    + 5 MM when ring rail is at starting  position.
07. Spindle rotation without vibration and correct concentricity of bobbin tube.
08. Select correct type of Traveller number with respect to count, material, ring  type, ring diameter, spindle speed,  yarn strength and life of the ring.
09. Anti balloon ring diameter = ring diameter +2 MM.
10. Maintain proper cop dimeter i.e. ring diameter - 3 MM
11. Correct selection of bottom curve shape in cop
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12. Use of heavier Traveller and higher spindle speeds leads to compact bobbin (cop) thus good cop  content TOP

13. Optimize the chase length i.e. maintain at least ring  diameter
14. Correct selection of ring rail starting position and doffing position
15. Feeding correct length of doff in display
16. Right selection of speed pattern
17. Running slow speed at starting and ending of cop

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Mr.K.T.Srinivasan, Assistant Factory Manager, Sri Lakshmi Saraswathi Textiles (Arni) Ltd, Arni, Tamilnadu
The optimized cop content is depending on the following factors:

1)  Ring diameter
2)  Lift
3)  Tube specification
4)  Traveller
5)  Spindle & spindle speed
6)  Machine setting
7)  Relative Humidity Percentage

Normally 45 to 50 grams of cop content is optimized for 36 & 38mm rings with 170mm lift.   Bigger diameter of 40 & 42 MM are used for better cop content, optimum speed & performance.   Half flange ring
will help for optimum cop content, as flange width is narrow, so ring to cop clearance   further try to reduce from 3 MM clearance to 2 MM

Lift: 170 MM & above can get higher cop content

Tube specification: wall thickness usually 2.2 MM is optimum, should not go more than this i.e. 2.6 & 3.0 MM.  

Taper 1:40 is normal; 1:64 is not advisable for higher cop content.   18.MM DUI is enough, more than this i.e. 20 MM DUI  will  not help for optimum cop content

Energy save spindles (lean spindles) will give more cop content, here higher DUI spindles should be avoided

Heavier Traveller will help for tight winding, so that we can further increase the cop diameter

Optimum & Higher spindle speed will bring compact & tight cop formation, which will help to improve cop content

From normal winding length 9 meters to 5 meters and above according to the count & yarn specification will give better cop content

Short chase length will extend to avoid slough off and help for better cop content

The ring rail setting for empties at top & bottom should be 10 MM

Cop former at bottom of the cop should optimized for 1 grams more

Dry-low  RH will give softer & loose cops , so optimum RH 55 % will help for better  working & cop content

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Mr.Murugaraj.S, Maintenance Manager Moon spinners Ltd, Nanguneri, Tamilnadu

Optimization of cop content in ring spinning:

Optimization of cop content is to get the maximum amount of cop content in ring spinning for the available parameters without affecting the working performance, efficiency, quality and without increasing
labour and power cost both in ring spinning and subsequent process of autoconer.

Optimization of cop content with various parameters in ring spinning:

The following ring spinning parameters influences the cop content.

Parameters Quantity Cop content Power cost Breakage rate Optimum quantity
S.No

1 Lift &Tube length High More More May be high As per count plan

Low Less Less Less

2 Ring diameter Bigger More More May be high As per count plan

Smaller Less Less Less

3 Ring Traveller Coarser More More May be high AS per CSP,Speed

Lighter Less Less Less

4 Chase length More More NA NA* Ring diameter +10%

Less Less NA NA*

5 Winding Length More More NA May be less* ***

Less Less NA May be more*

6 RH% More More NA May be less** As per raw material

Less Less NA May be more** BACK TO

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 7 Speed More More More High AS per breakage rate

Less Less Less Less

8 Empties Wall thickness More Less Less Less 2.6 MM wall thickness

9   Less More More More

Empties taper ratio 1:40 More More High As per breakage rate

1:64 Less Less Less

  Remarks

*    Slough off in auto coner to be checked.

**  Lapping performance to be considered.
*** Number  of winding coil per chase=Chase length/Yarn dia*sqrt(count spun)

The bobbin is formed in three parts based on the requirement of cop content:
1) Cop curved bottom base: More-Higher breakage but higher cop content.
2) Cylindrical body: Ring diameter 2 to 3 MM for finer count and 3 to 4 MM for coarser count.
3) Conical top: Top height less-Higher cop content. But slough off in auto coner to be considered. For Auto doff Ring frame gripper failure should to be considered.

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Mr.S.Jeedentran, Maintenance Head, Coimbatore Polytex Limited, Arasur, Tamilnadu

Optimizing of cop content maximum based on counts. For coarse count, we have to go for 3 to 4 MM clearance and finer count 2 to 3 MM clearance between cop and ring

Following factors are covered in Ring frame to optimize the cop content

1)  Winding length

2)  Spindle speed
3)  Traveller selection.
4)  Count
5)  Nature of material
6)  Fiber length and strength
7)  Lift

Volume-13, Issue-3, Aug-2013

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