Ring frame

Introduction to Ring Spinning Frame

 The ring spinning machine was invented in the year 1828 by the American Thorp.
Advantages of Ring Spinning over other Spinning
 It is universally applicable, most of the textile fibres can be spun to required fineness.
 The yarn spun from this machine demonstrate excellent quality features like uniform
structure and good strength.
 It is easy to operate as compared to other spinning machines.
 The “knowhow” for operation of the machine is well established.
 It is flexible as regard to quantities in terms of blend and lot sizes.

Disadvantages associated with ring spinning are

 More process stages. Roving stage exists as an extra process compared to the other
systems.
 Yarn breakages are more frequent as a result of ring traveller friction and yarn to air
drag forces. 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.

Operation of the Ring frame

 Attenuate the roving until the required fineness is achieved.
 To impart strength to fiber strand by twisting it.
 To wind up the resulting yarn in a form suitable for storage, transportation and further
processing.

Principles of operation
 Fig. 2 shows the operating parts of the ring frame and the principle of operation is
explained The roving bobbins (1) are creeled (A) in appropriate holders (3). Guide rails
(4) lead the rovings (2) into the drafting arrangement (5) which attenuates them to the
final required count.
 The drafting arrangement (B) is inclined at an angle of about 45 – 60 Degree. It is one of
the most important assemblies on the machine since it has considerable influence on
irregularities present in the yarn.
 After the drafting arrangement, the machine have twisting and winding zone (C).
 Upon leaving the front rollers, the emerging fine fiber strand (6) receives the twist needed
to give it strength. This twist is generated by the spindle, which rotates at high speed. Each
revolution of the spindle imparts one turn of twist to the fiber strand. Spinning of the yarn
is thus complete.
 In order to wind up the twisted yarn to bobbin mounted on Spindle( 8) , a traveller (9) is
required to cooperate with the spindle. The traveller moves on guide provided on the ring
(10) encircling the spindle.
 The traveller has no direct drive; instead, it is carried along by the yarn it is threaded with.
The speed of the traveller is lower than that of the spindle owing to significant friction
generated between the traveller and ring.
 This difference in speed enables winding of the yarn to bobbin.
 Winding of the yarn on to the bobbin is done by raising and lowering the ring rail. The
traverse stroke of the ring rail is less than that of the bobbin height. The ring rail must
therefore be raised by small amount after each layer of coils.
 Cross - section of the machine
 Fig. 3 shows the cross - section of a typical ring spinning machine. The ring frames are
two sided machines with the spinning positions located on both sides of the machine.

 Each spindle is a spinning position. The spindle rail houses the spindles. The creel housing
the feed roving bobbins are arranged in two rows on each side of the machine.

 The drafting arrangement is carried on the roller beams. Each intermediate section stands
on two feet adjustable in height by means of screws, thereby permitting easy leveling of
the machine.

 In modern machines, an autodoffer is also provided. Including the autodoffer, the width of
the machine varies from 800 to 1000 mm (up to 1400 mm when the doffer arm is swung
out). Today, the machine length can reach 50 m. Spindle gauges usually lie between 70
and 90 mm.
Ring Frame Machine Parts
The creel
 In design terms, the creel is a simple device. It can nevertheless, influence the
performance of the machine as well as the yarn quality by introducing number of faults. In
particular, if the roving bobbin does not unwind perfectly, then false draft can arise, or in
worst case it may lead to end breakage.

 To avoid this problem, the bobbin suspension

holders are provided in the machine which is
shown in Fig.1.

 This is provided for each spindle. Each holder

has in its lower portion the actual retainer device
for the bobbin tube.
 When the ring is pushed up as far as it will go by the upper end of a tube inserted into
the holder, the bobbin retainer swings out; when the ring is pushed up for second time,
the retainer is retracted and the bobbin can be withdrawn, for example when it is empty.

 The holders are suspended on ball bearings. A light brake arm presses gently against the
bobbin to prevent it rotating quickly. Modern creels take up a lot of space in breadth
since very large bobbins are used now.

The drafting arrangement

Influence on quality and economics
 If the quality is taken as the sole criterion, then the drafting arrangement is the most
important part of the machine.

 It influences mainly evenness and strength. The following aspects are therefore of great
significance:
 The type of drafting arrangement like the roller configuration
 Design of the drafting elements
 Precision of roller settings
 Selection of correct individual elements
 Choice of appropriate draft
 Service and maintenance

However, the drafting arrangement also exerts an influence on the economics of the
machine – directly through the end breakage rate, and indirectly through the draft level.

If higher drafts can be set in the drafting setup, then coarser roving can be used as feed
stock. This implies a higher production rate at the roving frame and thus a saving in roving
spindles, i.e. a reduction in the total no. of machines, space, personnel, and so on. On the
other hand, increase in draft usually adversely affect the yarn quality
Draft limits in ring frame
The break draft must be adapted to the total draft in each case since the main draft should not
exceed 25 to 30. Accordingly,
normal break drafts are:
Total draft up to 40 : 1.1 – 1.4 (often 1.14 – 1.25)
Strongly twisted roving : 1.3 – 1.5
Where the total draft exceeds 40 : 1.4 – 2.0

Design concepts in the structure of the drafting arrangement

 The ring spinning machines are fitted with 3 line double apron drafting arrangements.
They comprise of three lower fluted steel rollers to which the drive is applied.

 Top rollers carried in a pivoted weighting arm, are arranged above the fluted rollers and
are pressed against them.

 The strand contains only few fibers when it reaches the main drafting field; accordingly,
this is provided with a guide device consisting of an upper and a lower revolving apron.
 Normally, the top rollers are arranged as shown in Fig.2(a). The front top roller is set
slightly forward by a distance relative to the front bottom roller.

 While the middle top roller is arranged a short distance behind the middle bottom roller.
In each case the distance is about 2 – 4 mm. This position gives smooth running of the top
rollers; furthermore, the overhang of the front roller shortens the spinning triangle.

 This has a favorable influence on the end breakage rate.

 An alternative roller arrangement is offered by the INA Company in the so called V draft
drafting arrangement as shown in Fig 2(b). Here, the back pair of rollers are shifted
upwards and the back top roller is shifted rearward relative to the bottom roller. The large
encircling curve produces an additional fiber guidance zone.
 The Top Rollers
Classification
 Spinning mills operates with two types of top rollers (weighted rollers):
Those supported at both ends (in the draw frame and comber); and
Double boss roller in the roving frame and ring spinning machine.

 The second ones are supported in their centre sections by the weighting arm. They can
swing slightly relative to the axis of the bottom rollers. They are available in two versions:

 fixed rollers, with the two pressure bodies (Fig. 3) at left and right forming a rigid unit
which can only be rotated together and loose rollers, with the two pressure bodies
separately mounted and able to rotate independently of each other.

 A distinction is also made according to whether the roller bodies can be removed from the
shaft (removable shell), or are permanently attached to the shaft (non removable shell). The
roller bodies are mounted on single row or double row ball bearings.
 Coverings on the top rollers are made of synthetic rubber. The covering is drawn on to the
boss in the form of a short tube under tension, and is glued in place. This operation should
be carried out with the utmost care. Covering hardness can be classified into
Soft, Medium and Hard roller covers with the following shore hardness values:
Soft 60 degree to 70 degree shore
Medium 70 degree to 90 degree shore
Hard above 90 degree shore

 Covering with hardness less than 60 degree are normally unsuitable because they cannot
recover from the deformation caused by squeezing out on each revolution of the roller.

 Soft coverings have a great area of contact, enclose the fiber strand more completely and
therefore provide better guidance for the fibers. However, they also wear out significantly
faster and tend to form more laps. Where possible, therefore, harder coverings are used, for
example at the entrance to the drafting arrangement. At that point, a compact, self sufficient
strand, with a slight twist, is fed in and does not require any additional guidance.
 At the delivery, on the other hand, only few fibers remain in the strand and these exhibits
tendencies to slide apart. Additional fiber guidance is therefore advantageous. Accordingly,
coverings with hardness levels of the order 80 degree to 85 degree shore are mostly
used at the back roller, and 63 degree to 65 degree at the front roller.

 In the case of coarse and synthetic fibers, roller covers with high degree of shore hardness
are normally used to avoid of increased wear of roller cover and lapping tendency.

 Since the covering wear out, they must be buffed from time to time (after about 3000 to
4500 operating hours). This operation is carried out by special grinding machines. The
amount to be removed from the diameter lies in the region of 0.2 mm, but the total covering
thickness should never be reduced below 3.5 mm.
 Guidelines in selecting the cots
 For processing combed cotton, soft cots (60 to 65 degree shore hardness) will result in
lower U%, thin and thick places
 When softer cots are used, buffing frequency should be reduced to 45 to 90 days depending
upon the quality of the rubber cots, if the mill is aiming at very high consistent quality in
cotton counts.
 If the lapping tendency is very high when processing synthetic fibres for non critical end
uses, It is better to use 90 degree shore harness cots, to avoid cots damages. This will
improve the working and the yarn quality compared to working with 83 degree shore
hardness.
 If rubber cots damages are more due to lapping, frequent buffings as high as once in 30
days will be of great help to improve the working and quality. Of course,one should try to
work the ringframe without lapping.
Top roller Weighting
Methods of applying pressure
Three kinds of top roller weighting are presently in use:
 Spring weighting (most manufacturers)
 Pneumatic Weighting
 Magnetic Weighting (available from Saco Lowel)

Load – applying support arms are needed to carry the top rollers in the first two groups. These
support arms are mounted on shafts or tubes extending over the length of the machine behind
the rollers. They can be swung away from the bottom rollers to release pressure, and towards
the bottom rollers to apply it. This pendulum action is carried out with levers.
The Yarn Path
 The yarn produced by twisting at the delivery of the drafting arrangements is guided with
the aid of a thread guide to a position directly over the spindle.

 Before passing to winding up on the spindle, the yarn turns through a second guide position,
the balloon control ring.

 Winding on the spindle itself arises from interplay between the speed of the traveler rotating
on the ring and the rotational speed of the spindle.

 The later is therefore the third most important machine element, following the drafting
arrangement and the ring/traveller combination.

 Mechanically, the spindle is capable of speeds up to 28,000 rpm, but this maximum speed
cannot be exploited commercially because the traveller speed is limited.
Influence of the spindle on spinning
 Influence of the spindle on spinning.

 The running characteristics of a spindle, especially imbalance and eccentricity relative to

the ring, also affect yarn quality and of course the number of end breakages. Almost all yarn
parameters are disadvantageously affected by poorly running spindles.

 Hence, the mill must ensure at all times that centering of the spindles relative to the rings is
as accurate as possible.

 Since the ring and spindle form independent units and are able to shift relative to each other
in the operation, these two parts must be re- centered from time to time.

 Previously, this was done by shifting the spindle relative to the ring, but it is now usually
carried out by adjusting the ring. Mechanical or electronic devices are used for centering.
The Spindle
 A ring frame spindle consists of two separate parts, spindle center shaft and enclosed
bearing housing as shown in Fig. 1 and 2 . Usually, the center shaft is made of an aluminum
alloy and has slight taper, say 1:64.

 The bottom end of the shaft is in the form of a cap wharve. It is hollow and can therefore be
fitted over the spindle collar accommodated in the bearing housing. Wharve diameters of 19
to 22 mm are common at present. Bearing section is bolted firmly to ring rail by nut.

 The spindle bearing consists of 2 parts, a spindle collar bearing and a spindle step bearing.
Both parts are connected via housing. The spindle collar comprises a precision roller
bearing.
Spindle Drive
Basically, three groups of spindle drives can be distinguished,
 Tape drives
 Tangential belt drives
 Direct drives
Short staple spinning mills use practically only group drives, in the form of the 4spindle tape
drive, and tangential belt drives
In comparison with tangential belts, the 4spindle drive has the advantages of lower noise level
and energy consumption, and tapes are easier to replace.

4spindle tape drive

In this system, a tape drives two spindles on one side of the machine and a further two spindles
on the opposite side as shown in Fig.3. In running from the one machine side to the other, the
tape passes around a drive pulley. One or two tension pulleys ensure even and firm tension of
the drive tape.
Tangential belt drive
 Fig. 4 and 5 depict the different types of tangential belt drives for ring spinning. In this
drive, a belt extends from the suspended motor past the inner side of each spindle.

 A plurality of pressure rolls ensures even pressure of the belt on all spindles. Three basic
forms must be distinguished: single belt, double belt, and grouped drives.

 In the first case, one endless belt drives the spindles on both machine sides. In the second
case, two belts are provided, a first belt to drive the spindles on one side and a second belt
to drive the spindles of the other side.

 The double belt system gives better evenness of spindle revolutions. Where the single belt
principle is used, differences can arise owing to the considerable variation in tension along
the belt. This effect is especially marked in long machines. In grouped drives, groups of
spindles are driven by a single belt.
Yarn Guiding Devices (Lappets)

 Mounted directly above each spindle is a lappet designed to lead the yarn centrally over the
spindle axis as shown in Fig 6. The lappet consists of a thread guide made of bent wire ‘o’,
and a pivotable support arm ‘k’. This rail, along with the lappets can be raised and lowered.

 During winding of a cop, the lappet rail performs the same sequence of movements as the
ring rail, but with a shorter stroke, that is: Continual up and down movement during
winding of the layers, Continual upward shift through a small distance in accordance with
builder motion.

 As shown in figure, this movement guides ensures that differences in the balloon height
caused by changes in the ring rail positions do not become too large.

 Otherwise, excessive tension variation in the yarn would produce corresponding negative
effects on the ends down rates and the yarn characteristics.
Yarn Guiding Devices (Balloon Control Ring)
 Spindles used today are relatively long. The spacing between the ring and thread guide is
correspondingly long, thus giving a high balloon.

 A high balloon is associated with a large balloon diameter, causing space problems. The
large balloon dimensions lead to relatively high air drag on the yarn in the balloon. This in
turn caused increased deformation of the balloon curve out of the plane intersecting the
spindle axis. This deformation can lead to balloon instability; there is increased danger of
collapse.
 These above two problems could be nullified by an increase in yarn tension corresponding
with a heavier traveller. However, it may cause more end breakage rate.

 As shown in figure, this movement guides ensures that differences in the balloon height
caused by changes in the ring rail positions do not become too large. In order to avoid these
problems, balloon control rings are used, each dividing its balloon into two smaller sub -
balloons as shown in Fig.7.
Yarn Guiding Devices (Separators)

 Most ends down arise from breaks in the spinning triangle, because there very high forces
are exerted on a strand consisting of fibers which have not yet been fully bound together. If
a break occurs in the triangle, then the newly created free yarn end must be drawn to the
cop and wound onto it.

 During this process, the broken end thread end lashes around the spindle. In the absence of
protective devices, this broken end would be hurled into the neighboring yarn balloon and
would cause an end down on that spindle also.

 This procedure would be repeated continuously so that a wave of ends down would travel
along the row of spindles. In order to prevent this happening, separator plates of aluminum
or plastics material are arranged between the individual spindles as shown in Fig. 8.
 Drive System
 About 20% of production costs in a spinning mill fall under the heading “energy”, and of
these costs about two thirds are incurred in the ring spinning section.
 Power supplied to the ring spinning machine is absorbed by
The spindles 65 to 70%
The drafting arrangement 25%
The ring rail 5 to 10%

 Extreme yarn tension variations occur during winding of a cop and it would be useful to
reduce these tension variations by adjusting spindle speed. Fig.1 shows the ring rail
movement, yarn tension and ends down occurred in ring spinning operation.

 During winding of a cop layer, yarn tension rises as the ring rail moves upwards, i.e. from
the larger to the smaller winding diameter. The tension increase is significant, e.g. from 24
to 40 cN, and there is a corresponding effect on the number of end breaks.
 An investigation shows that most end breaks occur during raising of the ring rail in the
upper region. In order to hold yarn tension and the end break rate constant, spindle speed
should be reduced during raising of the ring rail (speed variation within the layer).

 A similar problem arises in relation to the package build taken as whole. At the start of
winding of a cop the balloon is very large, but at the finish it is relatively small. Yarn
tension changes accordingly. In this case also adjustment is needed via the spindle
revolutions (control of the basic spindle speed).

 Previously, both speed adjustments could be carried out with controlled operation of a
commutator motor. Today, usually only basic spindle revolutions are adjusted by variators,
direct current motors or frequency drives.

 The control programme should include at least a starting, a preliminary stage. An end stage
is often provided for winding of the uppermost portion of the cop; this can be identical to
the preliminary stage.
Motors used in Practice
 Alternating current with short circuited rotors (squirrel cage motors)
 Squirrel cage motors with star delta starters
 Squirrel cage motors with variators.
 Pole changing squirrel cage motors.
 Asynchronous motors with current controlled frequency; converters
 Alternating current, shunt wound commutator motors.
 Direct Current motors.
Squirrel cage motors with variators
 In this case, speed adjustment is not carried out at the motor itself, but by means of
adjustable grooved discs (Fig.2) in the belt drive, similar to a cone transmission.

 However, whereas in the cone transmission a required change of diameter relationships is

effected by shifting the belt axially of the cone drum pair, in the variators the change in
diameter is effected by shifting the belt radially on two v pulleys, each made up by a
respective pair of conically faced disc movable towards and away from each other.

 If the discs of one pulley are moved apart and those of the other pulley are moved together,
the drive belt passes onto a larger diameter of the one pulley, and a smaller diameter of the
other.
 The adjustment is effected, usually in steps, by a control device acting via pneumatic or
hydraulic pistons and lever mechanisms.

 The basic speed can be set manually. In Fig.2, Position V1 corresponds to the minimum
spindle speed when the winding just begins on the bare bobbin at the bottom most position.

 It can be noticed that the belt position on the driving pulley is in the lower location. Position
V2 corresponds to slightly speeds used to wind in the bottom and top portion of the cop.
Here, the belt is in a slightly raised location.

 Position V3 corresponds to the maximum speed when the winding is being done in the
middle portion of the cop. Here, the belt position is at the top most location.
Structure of the cop
 The cop is characteristic form of package produced by the ring spinning machine. It has
three clearly distinguishable parts: the lower, curved base, the middle, cylindrical part, and
the conical tip (Fig.3).

 About 10 mm of the tube is left free of coils at each of the upper and lower ends as shown
in Fig3(a). The tube is formed with a slight taper so that it is adapted exactly to the spindle.
The specific shape of the cop is built up by super position of a multitude of individual yarn
layers disposed in a conical arrangement.

 Each of these layers comprises a so called main winding and a cross winding as it can be
seen in Fig3(b). The main winding, which fulfils the primary yarn take up function, is
formed during the slow rise of the ring rail, whereas the more open cross winding forms
during the rapid descent. Since the cross windings lie at an angle between successive main
windings, they isolate the main windings from each other and thus prevent complete layers
being pulled off during
Winding Process
 The ring rail has to perform two movements; a continuous up and down movement in order
to lay one main and one cross winding (traverse cycle); and gradual raising in small steps
after each layer movement in order to fill the cop.

 Each of the movements has a very undesirable effect on the spinning conditions. In
particular, the size of the balloon and the winding diameter on the cop are subjected to
continual change. This leads directly to considerable tension variations during winding.

 In the winding of a layer, the ring rail is moved slowly but with increasing speed in the
upward direction and quickly but with decreasing speed downwards. This gives a ratio
between the length of yarn in the main and cross windings of about 2:1.

 The total length of a complete layer should not be greater than 5 m to facilitate unwinding.
The traverse stroke of the ring rail is ideal when it is about 15 18% greater than the ring
diameter.
The Builder Motion
 Fig.4 shows different parts of a typical builder mechanism used in ring frame. The ring rail
is suspended by belts from a disc mounted on the shaft; the full weight of the rail is carried
by the disc and generates a turning moment.

 At the other end of the shaft there is another disc; this second disc, acting via the chain and
chain drum, presses the level with the roller against the heart shaped eccentric.

 Owing to the rotation of the eccentric, the lever and the chain drum are continually raised
and lowered. This movement is transferred to the ring rail by way of the discs together with
the chain and belt, thus giving the traverse movement.

 Each time the lever moves down, it presses the catch to release the ratchet wheel, which
enables a slight rotation of the drum connected to the ratchet wheel. A short length of chain
is thus wound up on the drum. This leads to rotation of the disc, shaft, and disc (b), and
finally to a slight rise in position of the ring rail – the lift.
Building the Base
 The base of the cop is curved on its exterior in order to enable as much yarn as possible to
be taken up on the package. This curvature arises partly from the specific type of winding
itself, but is significantly reinforced by a mechanical auxiliary mechanism – the cam (N in
Fig.5), thumbs, deflector device or whatever other name the mechanism carries.

 As already explained, raising and lowering of the ring rail comes about because the
eccentric moves the lever up and down thus the disc is continually turned alternately to the
left and to the right. Disc carries the cam, which projects beyond the periphery of the disc
and thus forms a lobe of larger diameter than the rest of the disc.

 At the start of winding of cop, disc is located in the position shown in figure. In which the
lobe noticeably deflects the chain. The effect of this deflection is that the chain elongation
upon rising of the lever is not wholly transferred to the ring rail; part is lost as deflection at
N. The traverse stroke of the ring rail is no longer corresponds to the setting, since it is
shorter.
 However, since the length of yarn delivered during each traverse stroke is the same, the
volume per layer is increased, thereby generating the curvature.

 Now, in the further course of the spinning operation, the chain take up disc (T) is steadily
turned to the left in small steps by the ratchet wheel; the chain is thereby wound up on the
disc and thus shortened.

 Accordingly, disc (a) turns to the right in the same small steps and the cam is carried out of
line with the chain; finally, the complete elongation of the chain is passed on to the ring rail
and thereafter the cop takes its normal build.
Ring and Traveller
 In most cases, the limit to productivity of the ring spinning machine is defined by the
traveller in interdependence with the ring, and the yarn(Fig.1). It is correspondingly
important for the mill specialist to understand the significant factors and to act on them.
Optimal running conditions depend upon:
Materials of the ring and traveller
Surface characteristics
The form of the both elements
Wear resistance
Smoothness of running
Runningin conditions
Fiber lubrication.
The form of the ring
 These are classified into:
Lubricated rings (in woolen and worsted spinning); and
Unlubricated rings.

 The standard ring of the short staple spinning mill, i.e. the unlubricated type, can be
considered under the headings:
Single sided rings
Double sided rings.

 Single sided rings must be replaced by new ones after they are worn out; a double sided
ring(Fig.2b) worn on one side
and can be turned over and used on the second side. The later serves for mounting of the
ring while the first side is acting as
traveller guide.
The form of the ring
 For rings used in the short staple spinning mill, two dimensions are of prime importance:
the internal diameter and the flange width. Rings are available with the following internal
diameters (in mm): 36, 38, 40, 42, 45, 48, 51, and 54.
 Standards have been defined in relation to the flange sizes, as follows:

The “antiwedge” ring

Anti Wedge ring was the first high performance ring. It shows on enlarged flange inner side
and is markedly flattened on its upper surface. This change of form permitted use of
travelers with a lower center of gravity and precisely adapted bow (elliptical travelers),
which in turn allowed operation at higher speeds. Anti wedge rings and elliptical travelers
belong together and can be used only in combination.
The form of the ring
 These are classified into:
Lubricated rings (in woolen and worsted spinning); and
Unlubricated rings.

 The standard ring of the short staple spinning mill, i.e. the unlubricated type, can be
considered under the headings:
Single sided rings
Double sided rings.

 Single sided rings must be replaced by new ones after they are worn out; a double sided
ring(Fig.2b) worn on one side
and can be turned over and used on the second side. The later serves for mounting of the
ring while the first side is acting as
traveller guide.
The “Low Crown” ring
 In this ring, the curvature of the upper surface has been somewhat flattened compared
with normal rings (shown in Fig. 3). This gives more space for the passage of the yarn so
that the curvature of the traveller can also be reduced and the centre of gravity of the
traveler is lowered.
 In comparison with anti wedge ring, the low crown ring has the advantages that the space
provided for passages of the yarn is somewhat larger and that all current traveller shape
can be used, with the exception of the elliptical traveller. The low crown ring is today the
most widely used ring form.

Su Ring
Large surface contact for the traveller on the inner ring flange (better heart transfer)
Compensation of forces acting on the traveller.
Permits high traveller speeds.
Suitable for synthetic fibers.
Reduction in traveller wear.
FzR indicates the tensile
force exerted in the upward
direction by the yarn. The
FFK indicates the force
counteracting
FzR which arises because
the traveler is urged
downwards on to the conical
inner flange in response to
the high centrifugal force.
Material of the ring
 The ring should always be tough and hard on its exterior. The running surface in particular
deserves the closest attention. The surface layer must have high and even hardness in the
range 800 – 850 Vickers. The traveller hardness should be lower (650 – 700 Vickers). So
that wear occurs mainly on the traveller, which is cheaper and easier to replace. Surface
smoothness is also important. It should be high, but not too high, since otherwise a
lubricating film cannot build up.

The following materials are used

Flame – or induction hardened steel, to some extent;
Nitride steel; this is now rare since ablation can arise owing to the high surface hardness;
Carbo nitrided steel; this is the most common;

Chrome steel; this is found more rarely.

Required features for the ring
 Best quality raw material
 Good, but not too high, surface smoothness
 An even surface
 Good, even surface hardness, higher than that of the traveler
 It should have been running in as well as possible (optimal running in condition)
 Long operating life time
 Correct relationship between ring and bobbin tube diameter
 Horizontal disposition
 It should be exactly centered relative to the spindle.
Fiber lubrication on the ring
 It was initially assumed that cooperation between the ring and traveller involved metal to
metal friction. The spinner is fortunate that in fact this is not so, since metal to metal
friction would probably limit traveller speed to about 28 - 30 m/s.

 In reality, the traveller moves on a lubricating film which it builds up itself and which
consists primarily of cellulose and wax. This film arises from material abraded from the
fibers.

 If fiber particles are caught between the ring and traveller, then at high traveler speeds and
with correspondingly high centrifugal forces, the particles are partially ground to a paste of
small, colorless, transparent and extremely thin platelets. The traveler smoothens these out
to form a continuous running surface.
 The position, form and structure of the lubricating film is dependent upon many factors
including yarn fineness, yarn structure, fiber raw material, traveller mass, traveller speed
and height of the traveller bow.

 In spinning of yarns finer than, say, Ne 80, no fiber lubrication can be expected because
traveller mass and hence centrifugal force are low. Maximum traveller speed is therefore
lower than that in spinning of coarser yarns.

 Modern ring/traveller combinations with well functioning fiber lubrication enable traveler
speeds in extreme cases up to 40 m/sec.
Running in a new ring
 If a worn ring is replaced by a new one, fiber lubrication is absent from the replacement.
Over a certain period, only metal to metal friction is present at the contacting surfaces of the
ring and traveller.

 This is very critical phase, since the new ring can very soon
suffer damage from pitting, and also owing to the risk of welding. Hence, ring
manufacturers have established precise rules for this running in phase.

 New rings should not be degreased, but only rubbed over with a dry cloth.
Use either the correct traveller with a 15-20% reduction in spindle speed, or the normal
spindle speed with a traveller 12 numbers lighter than usual.

 Between times, the spindle speed can be increased in steps.

 The first traveller change should be carried out after 15 min.
 The second traveller changes should be carried out after 30 min.
 Third traveller change should take place after 1 to 1.5 hrs.
 The fourth traveller changes are to be made after the second and third doffs.
 Traveller changes should again takes place after fifth and eight doffs.
The Traveller
 The traveller imparts twist to the yarn, and enables winding of the yarn on to the cop. The
length wound on to the cop per unit time corresponds to the difference between speed of
spindle and traveller.

 And this should be equal to that of front roller delivery speed. The speed difference due to
lagging of the traveller relative to the spindle, since the traveller does not have a drive of its
own but is dragged along behind the spindle is known as ‘Traveller Lag’.

 High contact pressure (up to 35 N/mm2) is generated between the ring and traveler during
winding, mainly due to centrifugal force. The pressure induces strong frictional forces
which in turn lead to generation of significant amount of heat.

 This is the kernel of the ring/traveller problem. The low mass of the traveller does not
permit dissipation of heat in the short time available. As a result the traveller speed is
limited.
Classification
 Travellers are required to wind up yarns of very different types: coarse/fine; smooth/hairy;
compact; voluminous; strong/weak; natural fiber/synthetic fiber. These widely varying yarn
types cannot all be spun using just one traveller –variety of travellers are needed. Difference
are found in: form;
 mass;
 raw material;
 finishing treatment of the material;
 wire profile;
 size of the yarn clearance opening for the thread.

 Spinners must make wise decision according to conditions.

Form of Traveller
 Different traveller shapes are shown in Fig. 5
Form of Traveller
 The traveller must be shaped to correspond exactly with the rings in the contact zone, so
that a single contact surface, with the greatest possible surface area, is created between
these two elements. The bow of the traveller should be as flat as possible, in order to keep
the centre of gravity low and thereby improve smoothness of running. The following shapes
are in use in the shortstaple spinning mill:
 (a) C –traveller
(b) Flat or oval traveller
(c) Elliptical traveller
(d) N –traveller
The material of Traveller
The traveller should:
 Generate as little heat as possible.
 Quickly distribute the generated heat from the area where it develops (the contact surface)
over the whole volume of the traveler.
 Transfer this heat rapidly to the ring and the air.
 Be elastic, so that the traveller will not break as it is pushed on to the ring.
 Exhibit high wear resistance;
 but Be somewhat less hard than the ring, because the traveller must wear away in use in
preference to the ring.

In view of these requirements, travellers used in the short staple spinning mill are almost
exclusively made of steel. However, pure steel does not optimally fulfill the first three
requirements. Accordingly, traveller manufacturers have made efforts over several
decades to improve running properties by surface treatment. Suitable processes for this
purpose are:
 Electroplating, in which the traveller receives a coating of one or most metallic layers, e.g.
nickel and silver; or
 Chemical treatment of the surface to reduce friction and pitting.
Traveller Mass
 Traveller mass determines the magnitude of frictional forces between the traveller and the
ring, and these in turn determine the winding and balloon tension.

 If traveller mass is too small, the balloon will be too big and the cop too soft; material take
up in the cop will be low. An unduly high traveller mass leads to high yarn tension and
many end breaks. Accordingly, the mass of the traveller must be matched exactly to both
the yarn (fineness, strength) and the spindle speed.

 If a choice is available between two traveller weights, then the heavier is normally selected,
since it will give greater cop weight, smoother running of the traveller and better transfer of
heat out of the traveller and better transfer of heat out of the traveller.
Traveller Clearer
 A yarn consists of fibers that are bound into the structure more or less effectively, but that
are in any event relatively short. It is therefore inevitable that as the yarn runs through the
traveller, some fibers will be detached.

 For the most part they float away into the atmosphere, but some remain caught on the
traveller. These retained fibers can accumulate until they form a tuft, and the resulting
increase in traveller mass can lead to much increased yarn tension which finally can induce
an end break.

 Fiber removing devices, so called traveller clearers are mounted close to the ring in order to
prevent formation of such fiber accumulations. They should be set as close as possible to
the traveller without, however, interfering with its movements. Exact setting is very
important.
Traveller No. or Traveller size
 Here the unit is 10 travelers. If 10 travelers weight is 10 grain then, the no. is one. If it is 11
grain then no. is 2 and so on. Again, if the wt. of 10 travelers is 9 grain then, traveler size is
1/0 or 1-0. If it is 8 grain then the size is 2/0 or 2-0 and so on. That is, if the no. is less, then
the traveler is light. In practice, travelers are available from no. 1 to 10 (Heavy traveler) and
reversely 1/0 to 20/0 (Lighter). Commonly, for finer yarn light traveler is used and for
coarser yarn heavy traveler is used.
 Recommended traveler no. for various yarn counts:
Count (Ne) Traveller No.
16 2
20 1-2/0
30 3/0-4/0
40 6/0-8/0
50 10/0-12/0
60 13/0-15/0
80 16/0-19/0
100 19/0-20/0
Factors Considered for Selection of a Traveller:
 Yarn count: Higher the yarn count, lower will be the traveler weight.
 Spindle Speed: If the spindle speed is high, then the yarn tension will be high. So lighter
traveler should be used to minimize tension.
 Ring dia: For same spindle speed and count, with the increase of ring diameter yarn
tension as well as frictional area increases. So traveler should be lighter.
 Empty bobbin dia: When empty bobbin dia decreases, winding angle decreases resulting a
higher yarn tension. So a light traveler should be used.
 Lift of bobbin: If the lift of bobbin increases yarn tension will be higher. So traveler weight
should be less.
 Cross section of traveler: We know, if frictional area increases, lighter traveler should be
light.
For flat frictional area increases, traveler weight decreases.
For semi circular, frictional area decreases, traveler weight increases.
For circular, frictional area decreases, traveler weight increases.
Yarn Tension in Ring Spinning

 The power provided by winding tension in the spinning system is expended by means of the
following ways.
I. To overcome ring traveller friction.
II. To overcome yarn traveller friction.
III. To overcome the resistance of air to the rotation of
a) A loop of yarn between thread guide and the traveller.
b) The portion of yarn between the traveller and the package.

 Assuming that the traveller contacts the ring at one point only, the conditions for
equilibrium are: Balancing the horizontal components From the Fig. 1,
Spinning Balloons
 A finite balloon can be formed only when there is some mechanism for maintaining a
tension in the yarn. Fig.1 shows the relation between centripetal force, tension and work
done.

Tv – Rate of doing work

2T = mrω2 ......................................(1)
 Centrifugal force merely balances the tension existing in the yarn. In ring spinning, the
main source of tension in yarn is the friction between ring and traveler.
Process Control in Ring Spinning
 Process control in the ring frame section is important since it affects the properties of the
final yarns directly. Long term variation should not be normally introduced by the ring
frame, assuming that all ring frames have the same draft, roller grip is adequate and no
slippage occurs. It should be ensured that all ring frames of the same make and running in
the same count have the same change pinion and back roller wheels.

 Between Bobbin Variation

 Frame to frame differences in count due to varying pinions or back roller wheels are found
to be present in some mills.
 Count also differs significantly between days which can be attributed to changes in relative
humidity, incorrect pinion changes and also shifts in the average weight of lap.
 Differences in hank between machines in the preparatory department and channelizing of
material are the other sources of count variation.
 Adequate attention is not paid by some of the mills to the proper feed of the creel bobbins.
 Excessive variation in tension between bobbins due to differences in spindle speeds, spindle
out of centre etc., can also result in between bobbin variation.
 Slippage of top rollers due to poor lubrication or insufficient weighting is also one of the
causes for count variation.

 Strength Variation in Ring Frame

 Strength variation could be largely dependent on count variation. It is observed that about
50% of the variation in strength as well as about 50% of the variation in strength CV mainly
due to count variation.

 Variation in humidity is one of the major causes for the relatively higher strength variation.

 Some of the causes for the relatively high strength variation are excessive yarn unevenness,
difference in twist, mechanical imperfections in drafting like eccentric rollers, worn aprons,
inadequate top roller pressure in draw frames and ring frames etc., and thick and thin places
arising from the spindle vibration.
 Excessive variation in tension between bobbins due to differences in spindle speeds, spindle
out of centre etc., can also result in between bobbin variation.
 Slippage of top rollers due to poor lubrication or insufficient weighting is also one of the
causes for count variation.

 Strength Variation in Ring Frame

 Strength variation could be largely dependent on count variation. It is observed that about
50% of the variation in strength as well as about 50% of the variation in strength CV mainly
due to count variation.

 Variation in humidity is one of the major causes for the relatively higher strength variation.

 Some of the causes for the relatively high strength variation are excessive yarn unevenness,
difference in twist, mechanical imperfections in drafting like eccentric rollers, worn aprons,
inadequate top roller pressure in draw frames and ring frames etc., and thick and thin places
arising from the spindle vibration.
 Yarn Irregularity:
 Table.1 provides the norms for Yarn Unevenness (U %) for different counts of carded and
combed yarns. The major process parameters that affect the yarn irregularity are as follows:

Material Count Good Average Poor Material Count Good Average Poor

20s 12.0 13.5 15.0 30s 11.0 12.0 13.0

30s 12.5 14.0 15.5 40s 12.0 13.0 14.0

Carded Combed
40s 14.5 16.0 17.5 60s 12.5 13.5 14.5

60s 15.0 16.5 18.0 80s 13.0 14.0 15.0

Table 1 : Norms for Yarn Unevenness (U %)

 Setting between the rollers
In order to avoid the creation of drafting waves and to reduce short term irregularity
(U %) of yarn, proper roller settings must be adopted. A back zone setting of 55 mm
for fibers with length up to 30mm and a back zone setting of 60 mm for fibers with
length greater than 30 mm will help to produce yarns with minimum irregularity.

 Top roller Pressure & Shore Hardness

 Insufficient loading of top rollers leads to erratic movement of the fibers due to fiber slip
between the drafting rollers. This, in turn, will lead to high level of short term unevenness
of yarn
 Studies show that a top roller pressure of 18 kg (for cotton spinning) improves yarn
evenness by 1 U% and reduces thick and thin places by 15 to 40% in different counts as
compared to the 9 kg pressure.
 Use of soft cots (shore hardness of 70 o to 75 o) generally improves yarn quality by
reducing slip between the cot and the bottom fluted roller.
 Draft Distribution
 The total draft and break draft employed in spinning influence the amount of irregularity
added in spinning and depend on the quality of roving and condition of the ring frame.
 Break draft in ring frame is mainly to break the mild twist in the roving. Higher the break
draft, greater will be the fiber breakage at the back zone. If the TM in the roving is higher,
then comparatively higher break drafts could be employed. While using higher break draft
the back roller setting should be wider to obtain good results.

TPI in Roving Break Draft in R/F

1.38 1.2

1.94 1.3

2.35 1.4

Break Draft in Ring Frame for different Roving TPI

 Apron Spacing
 Cradle opening in ring frame contributes to the tune of 60 to 80% of the incidence of thick
and thin places and slubs in the yarn.
 Wider the cradle opening, lesser will be the control of fibers between aprons leading to thin
places in the yarn. Narrower the cradle opening, greater will be the strain on the fibers
between the aprons, leading to the increased fiber damaged and resistance to drafting which
will result in undrafted ends in the yarn.

Count (Ne) Apron Spacer(mm)

Upto 20s 4.0

21s to 40s 3.5

41s to 60s 3.0

61s to 80s 2.5

Apron Spacer for different Yarn Counts

Sometimes less is more….
Thank you