Winding in textile

Winding in textile manufacturing, winding refers to the process of transferring yarn or thread from one package to another, with the aim of preparing the yarn for subsequent processes, creating a larger package for better efficiency, or improving yarn quality by removing defects or knots. While winding can be done manually, it is usually automated using specialized machinery called winders, which can handle various yarn types and package sizes and perform different winding techniques, including precision winding, soft package winding, and cheese winding. Winding is crucial in textile manufacturing since improper winding can lead to issues such as yarn breakage, uneven tension, and defects in the finished fabric, making it essential to carefully control the winding process for quality and performance outcomes.

Winding

Winding is a process in which yarn from ring bobbins is wound into a convenient form of package. Transferring a yarn from one type of package, more suitable for the subsequent process, is also called winding. It occurs both in spinning & weaving.

Object of winding

1. Transfer yarn to a suitable package.
2. To remove yarn faults.
3. To have desire length of yarn.
4. To improve the efficiency of machine for the next process.
5. To empty spinners bobbin so that it can be used again.
6. To make quality fabric

Winding rate

The winding rate is the speed at which the yarn is wound on the package surface. In the case of a parallel package, the traverse is very slow, so the winding rat is approximately equal to the surface speed.

Classification of Winding

1. According to density
   1. Precision winding
   1. Non precision winding
2. According to types of package
   1. Cone winding
   1. Pirn winding
   1. Flanged bobbin winding
   1. Cheese winding
   1. Cop winding
   2. According to the build of the package
      1. Parallel winding
      1. Near parallel winding
      2. Cross Winding
3. According to method of drive
   • Positive or direct drive
   • Negative or frictional or indirect drive

• According to the method of drive
  • Positive or direct drive
  • Negative or frictional or indirect drive

1. According to feature of automation
   • Conventional Winding
   • Modern Winding

Types of WInding With Photo

Withdrawal process

Unwinding yarn from package

It is Two types

Side withdrawal

In this method the yarn package is rotated and

therefore the yarn does not rotate during withdrawal.

• The yarn twist does not change.
• Requires additional energy and equipment.
• Occur tension variation.

Over-end withdrawal

In this system, the yarn package does not rotate. Yarn withdrawal from over of the package.

• Balloon is formed

Auxiliary function of winding

1. Creeling
2. Piecing
3. Doffing

Winding Machine

There are several types of winding machine.

1. Pirn winding machine
   1. Cone winding machine
   1. Cheese winding machine
   1. Falnged bobbin winding machine

Tensioning and Cleaning Zone

In this region, proper tension is given to the yarn for a desired package density and body.

The typical components of this region are

1. Guides
2. Tension device
3. Cleaning device
4. Stop motion

Guides

Show the path of the yarn.

Two types of guide

1. Type-A, Closed guide
2. Type-B, Open guide

Tension Device

The tension device maintain a proper tension in the yarn to achieve a uniform package density.

It also serves as a detector for excessively weak spot.

There are three main types of tension device.

1. Capstan tensioner (or Multiplicative)

Tension device mathematical equation

𝑇_𝑜𝑢𝑡 = 𝑇_𝑖𝑛×𝑒^𝜇𝛼

• Additive tensioner

𝑇_𝑜𝑢𝑡 = 𝑇_𝑖𝑛 + 2𝜇𝑁

• Combined tensioner

𝜇 = 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡

𝛼 = 𝑓r𝑖𝑐𝑡𝑖𝑜𝑛 𝑎𝑛𝑔(𝑟𝑎𝑑𝑖𝑎𝑛) e = 2.718

N = Applied force

𝑇_𝑜𝑢𝑡 = 𝑇_𝑖𝑛×𝑒^𝜇𝛼+𝑇_𝑖𝑛+2𝜇𝑁

Yarn Cleaner

The purpose of a yarn detector is to remove thin and thick places.

Yarn detectors are usually two types:

1. Mechanical
2. Electrical

Stop Motion

The purpose of a stop motion is to stop winding when the yarn breaks or runs out.

Traversing Mechanisms

A mechanism which is used to distribute the yarn axially along the package is called traversing mechanism.

1. In the friction drive winder-a traversing groove cut into the friction drum is used.
2. In the spindle drive-a reciprocating traverse is used.

Pirn Winding Machine

Cone Winding Machine

Winding Efficiency

Winding efficiency=  𝐴𝑐𝑡𝑢𝑎𝑙 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 * 100 /𝐶𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛

Winding efficiency depends on:

• Spindle or drum speed
  • Yarn count
  • Yarn quality
  • Worker efficiency
  • Humidity
  • Worker load per worker
  • Maintenance and over hauling
  • Power failure
  • Creeling time
  • Doffing time

Winding Defects, Causes and Remedies

1. Stitches or ‘Jali’ on cone
2. Soft nose or base
3. Patterning or ribboning
4. Collapsed cone
5. Ring shaped cone
6. Bell shaped cone

Ballooning:

The rotation applied to departing yarn during unwinding from a stationary bobbin, the yarn is thrown by centrifugal force away from the bobbin axis and circumscribes in space of plane is called balloon. This phenomenon is called ballooning.

Factors influence of affect the size of balloon:

1. Count of the yarn
2. Winding speed
3. Size or shape of the package
4. Position of guide
5. Lift of the package

  Winding Calculation

Formula:

Winding efficiency=  𝐴𝑐𝑡𝑢𝑎𝑙 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 * 100 /𝐶𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛

• Production of machine =Surface speed of drum × Time × No. of drums × Efficiency% × Wastage% × Weight per unit length

The surface speed of drum = π × 𝑑𝑖𝑎 𝑜𝑓 𝑑𝑟𝑢𝑚 × 𝑅𝑃𝑀 𝑜𝑓 𝑑𝑟𝑢𝑚

• For English Count, Weight of per yards = 1/(840×𝑌𝑎𝑟𝑛 𝐶𝑜𝑢𝑛𝑡)pound

• For Jute Count, Weight of per yards = count/14400 pound

• For Tex Count, Weight of per meter = count/14400 gm

Math

• Calculate the time required for winding 1000 kg of 20′^𝑆 cotton on 10 drums. The actual production/drum/minute 600 yds.

• The winding drum of a high speed cone winding having a diameter of 3 inch makes 2870 rpm. The actual amount of yarn wound in 9hrs was found to be 332,838 yds. What the efficiency?

• Calculate the production in lbs per shift of 8 hours of a cone winding machine considering the following particulars: RPM 1200, Diameter of winding of drum 4”, No. of drums 120, Yarn count 32 Ne, Efficiency 70%.

• Calculate the no. of drums required for winding 750 kg of 25 Tex cotton yarn in a day of 8 hours, if the actual production per drum per minute is 1040 meters.
• Calculate the production in kg and hank of 40 high speed winding machine, each having 25 drums for a shift of 8 hours. Winding rate per drum is 600 m/min. Efficiency 85%, wastage 0.25% and yarn count 24’s.
• Calculate the time that would be needed to wind 2000 kg of 40 Tex yarn. The number of drums available is 100, and the actual production per drum per minute is 1000 meters.

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