Winding: The process of transferring yarn from ring bobbins, hanks, cone, etc. A suitable package is called winding.

Objects of Winding: y To transfer yarn from one package to another package, this can be conveniently used for weaving purpose. y To remove yarn faults like hairiness slabs naps and foreign mailers. y To produce long length of yarn by serially joining one yarn package with another. y To clean yarn. y To improve the quality of yarns. Requirement of winding: 1. 2. 3. 4. 5. 6. Minimum fault level. No damage of yarns. Must permit easy unwinding/ with draw. Suitable size and shape of the package. Economical condition and tightness. Above all the process must be profitable.

Type of winding package: According to method of winding: 1. Parallel wound package. 2. Near parallel wound packages. 3. Cross wound package.

Parallel wound package: This package comprises many threaded laid parallel to one another as in a warp beam . It is necessary to have a flanged package.

Example: Warpers, Beam, Weavers beam. Advantages:

1. 2. 3. 4. 5. Disadvantage:

Much thread can be wind at a time. More yarn density in the package . Side withdrawal possible. During winding no change of twist During winding no need to traversing mechanism.

1. Need flanged bobbin. 2. Need separate mechanism during unwinding. 3. Not possible over withdraw.

Near parallel wound package: This comprises one or more threads laid very nearly parallel to the layers already existing on the package. Ex: Pirn, Cop, Flange Bobbin etc.

Advantages: 1. 2. 3. 4. Disadvantage: 1. Side withdraw is not possible. 2. During winding need traversing mechanism. Cross wound package: This type usually consists of single thread which is laid on the package at on appreciable helix angle, So that the layers cross one another and give stability. Ex: Cone, Cheese, Spool. Normally no need to flange bobbin. Over withdrawal can be possible. During winding no change of twist. The package is comparatively stable.

Cone Advantages:

Cheese

1. Package stable due to cross wound. 2. Over withdrawal is possible. 3. During unwinding no need to separate mechanism. Disadvantages:

1. 2. 3. 4. 5.

The amount of yarn in the package is less due to low density. Twist may be changed during unwinding. Side withdrawal is not possible Need traversing mechanism. Only a single yarn can be wind.

Type of winding Machine: According to package i. ii. iii. iv. v. vi. vii. Pirn Winding Machine. Cop Winding Machine. Spool Winding Machine. Cone Winding Machine. Cheese Winding Machine. Warp Winding Machine. Flange Winding Machine.

According to Winding i. Precision winding Machine ii. Non-precision Winding Machine

According to winding: Precision Winding m/c: In this type of winding successive coils of yarn are laid parallel or near parallel to each other. Hence a very dance package is formed which contains maximum yarn in a given volume. Ex: Parallel and near parallel wound package. Non-Precision winding m/c: This type of winding the package contains of a single thread which is laid on the package at on appreciable helix angle. So that the layers cross one another and give stability. Method of Driving: Indirect/ surface contact Driving: Surface contact between the outer surface on the yarn on the package and a drum or roller. This given a contact surface speed to the package and the yarn is taken up at content speed .

Package

m/c
Pulley

Motor Pulley

Package Dia

Direct Package driving at constant speed/RPM: Directly driving package at a constant angular speed. This cause the yarn takes up speed to very as the size of the package change.

Y m/c Pulley

Motor Pulley

Package Dia

Directly Package driving at variable speed/RPM: To give constant yarn speed it is necessary to change the rotation speed to very inversely with the package. Y

Package Dia

Balloon Theory: During yarn winding and unwinding due to centrifugal force balloon in formed which is known as balloon theory.

Factors Influence the size of balloon: a) Count of yarn : Fine count Lower balloon size Case Count Higher Balloon size b) Winding and Unwinding rate/speed: Higher SpeedHigher Balloon Size Lower Speed. Lower Balloon Size c) Size and shape of package: Large package Greater balloon size d) Position of guide: Greater distance.. Higher balloon size e) Lift of package: Greater lift.. Large balloon size

Yarn Guide: Due to vibratory force in the yarn path, the yarn mist be controlled by placing guide along the yarn path, Guides are normally made of hand , smooth, steel or ceramic. Yarn guide usually two type

1. A yarn end is required for threading y Take extra time in threading so speed operation of decreased y More friction is occurred.

Ceramic Insert

Trumpet

Brush

2. A yarn end is not required for threading y Easy & speed of operation is increased.

Pig Tail

Slotted

Post Guide

Guide

Auxiliary function of winding: 1. Creeling 2. Piceing 3. Doffing Yarn Cleaner: The yarn may contain many undesirable matters which make then interior. It may the thick and thin places, neps, slubs, foreign matters which may trouble in the process. The operations of moving this undesirable element of yarn is called cleaning and the device which and used for cleaning is known as yarn cleans. Yarn cleaning device: The device which can control the yarn tension is called tensioning device. Importance of tensioning device: 5

1. Too height a tension: y Can damage yarn. y Breakage rate may greater. y Inherent property of yarn may change y Elongation property of yarn may change y Weaken the thin place of yarn 2. Too low a tension: y Permit unstable or loose package which will not unwound cleanly y Variation in yarn tension in different part of a wound package can cause undesirable effect. Requirements of tension device y y y y y y y y y y y y y The device must be reliable to central uniformly in tension . It must be easily threaded It must nether introduction or magnify tension variation It must not introduce differences in twist It must not be affected by wear It must be easily adjusted It must not be affected by the presence of dirt and oil. It must not encourage the collection of dirt and lint It must be capable of easy cleaning The operating surface must be smooth It must be cheap It must be simple in design and operation It must not cause damage of yarn

Type of tension Device: 1. Capstan tensioner: In is a simple from of tension. It worker by deflecting the yarn around fixed post induces a capstan effect which follow the low. Out put tension = Input tension em T2 = T1 em Where
1

<
2

M = Co-efficient of friction
=Angel of lap = ( 1+ 2+ 3+ ) e = Constant = 2.718

T2

Capstan Tensioner

2. Additive tension: In this device added load or spring is used to give a fixed increment of tension. The yarn yarn passed through middle of two surfaces in contact and force is applied from above to give suitable tension to the yarn.

F T1

T2= T1+2M F F = Applied force M= Co-efficient of frictions

T2
Additive tensioner

3. Combined tensioner: It is the combined system of capstan and additive tensioner. This device permits the tension level to be the raised to any desired extent. T2=T1 e M +T1+2mf

T2

T1

Combined Tensioner

4. Lever or Automatic type tension:

Spring Applied Force

Spring Loaded

Tension is Controlled automatically

Disc Tension Tension is Yarn Operate leveler which Alter springs loading or dise and alters tension.

Winding Efficiency: The ratio of actual production and calculate production is called winding efficiency and expresses as percentage.

Reasons of lower efficiency: 1. 2. 3. 4. 5. 6. 7. 8. 9. Power failure Maintains/Over hauling Absention Strike Natural disaster Labour Unrest Labour unskillness Shortage of space parts & raw materials Management problem.

Related Factors of Winding efficiency: 1. Spindle speed/ Drum speed 2. Yarn Count

3. Yarn Quality 4. Workers efficiency 5. Humidity 6. Work load per worker 7. Maintenance 8. Power failure 9. Creeling time 10. Doffing time 11. Capacity Utilization Faults/Defects in winding: 1. Formation of patches on the yarn: During the process if winding cotton yarn lose fiber detach themselves and as a result a considerable amount of fluff gather on various parts of the machine and is carried for word by the thread, firming patches, these patches being soft and creed various problems. Proper cleaning of the yarn and machines part required as a remedy. 2. Incorrect winding speed: Cause yarn breakage case of excessive winding speed and Decrease production in case of low winding speed and the package will be soft. 3. Excessive winding: Excessive full cause the yarn to slip off the sides and thus spoil it. Excessive full pirns cannot be fitted into the shuttle or it will rub the inner shuttle wall to cause breakage correct amount of yarn. 4. Sift bobbin: It the yarn is wound at a low tension, the package will be soft and the yarn coils will migrate to cause obstruction breakage during unwinding. The soft package also capacity-winding at proper tension. 5. Dirty/Faulty yarn in the package: It the slab cutter cleaning device is not used the yarn Will contains dirts, slabs, trashes, in the yarn use slab cutter/yarn cleaning device. 6. Incorrect shape of the package: (i) (ii) (iii) (iv) This may be due to; Faulty traversing motion. Faulty yarn guide. In case of cone or cheese winding the groove in the drum may be defective. Faulty building device.

7. Slack knots or knots with long tail:

Slack knots cause problem during weaving and knots with long tail because yarn breakage use auto knotted.

y Time requirement in hour = y Time requirement in hour =

1. A cone made on a modern high speed cone winding m/c, contains 4lbs of 20,s cotton yarn calculate the length of yarn in gards. Solve: Length of yarn in Hank= wt.in lbscount = 4 20 = 80 Hank . . Length of yarn in yards = 80 840 = 67200 yds (Ans) 2. A set of 4 warperss beam each containing 95 lbs of yarn is made from 500 boobin. If the cotton of yarn is 42, s cotton, what should be the length and weight of the yarn on each bobbin? Allow 5% waste and material left on bobbins. Slove: Total wt.of yarn of beams = warpers beamweight = 4 95 lbs = 380 lbs Total w.t of yarn on bobbin = 380 + ( ) = 399 lbs Wt. of yarn on each bobbin = = 798 lbs. Length of yarn on each bobbin = 79842840 = 28153.44 yds. (Ans)

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