WINDING

WINDING
The process of transferring yarn from ring bobbins, hanks, cones
etc onto a suitable package is called Winding.
Object:
1. To transfer the yarn from spinner’s package onto a
convenient form of package which will facilitate weaving
or the net process of yarn preparation.
2. To have desired length of yarn on the package.
3. To remove yarn fault and improve quality.
4.To make quality fabric.
5. To store the yarn properly.
Winding requirements:

1.The fault level in the yarn must be reduced to an acceptable level.

2.The yarn must not be damaged in any way in the winding process.
3.The yarn must be wound in such a way as to permit unwinding in the following
processes with a minimum of difficulty at the required speeds.
4.The package size, shape, and build must be the most technologically suitable for
the particular end use.
5.The package size should be controlled to meet the particular economic
requirements.
6.The winding operation must be geared to give the best possible economic
performance of the whole process of fabric manufacturing.
 Name of Packages

Cheese Cone Pirn

Names of the packages with their uses:

1. Cheese packages
2. Cone packages
3. Pirn packages
4. Flanged bobbin
5. Spool packages
6. Cop packages
 Types of Packages
Types of packages
according to winding
process
• The parallel wound pkg
• The Near parallel
Wound pkg
• Cross wound pkg
Yarn Packages:
1.Parallel wound package:
This package comprises many yarns laid parallel to one another as in a warp
beam. It is necessary to have a flanged package. For instance, Warper’s Beam,
Weaver’s Beam.

Advantages:
a) Many yarns can be wound at a time.
b) More yarn density in the winding package.
c) Side withdrawal is possible.
d) During unwinding no change of twist.
e) During winding no need to traversing.
Disadvantages:
a) Need flanged packages.
b) Need separate mechanism during unwinding.
c) Over withdrawal is not possible.
2.Near Parallel wound package:
This package comprises one or more yarns which are laid very nearly
parallel to the layers already existing on the package. For instance,
Pirn, Cop.
Advantages:
a)Normally no need of flanged package.
b) Over withdrawal is possible.
c) The package is comparatively stable.

Disadvantages:
•During unwinding twist may be changed.
•Side withdrawal is not possible.
•During winding need traversing mechanism.
3. Cross wound package:
This type usually consists of a single yarn which is laid on the
package at an appreciable helix angle. So that the layers cross
one another and give stability. For example, Cone, Cheese etc.

Advantages:
a)Package stable due to cross wound.
b) Over withdrawal is possible.
c) During unwinding no need of separate mechanism.

Disadvantages:
a) The amount of yarn in the package is less due to low density.
b) Twist will be changed during unwinding.
Yarn Withdrawal:
There are two ways in which a yarn package may be
unwound:
1.Side withdrawal
2.Over end withdrawal/over withdrawal.
1.Side Withdrawal:

•Package must rotate positively or negatively.

•Expensive if package is rotated positively.
•Yarn twist unchanged.
•Low unwinding speed.

2.Over end withdrawal:

•Package is stationary
•Yarn twist changes during unwinding.
•High unwinding speed.
Types of winding machine:

1. According to winding package:

a) Cheese Winding Machine
b) Cone Winding Machine
c) Pirn Winding Machine
d) Flange Bobbin Winding Machine
e) Cop Winding Machine
f) Spool Winding Machine

2. According to Winding:
a) Precision Winding Machine (parallel or near parallel package)
b) Non-Precision Winding Machine (cross wound package)

3. According to Drive:
a) Direct Drive winding machine.
b) Indirect Drive winding machine.
Tensioning Device:
During winding yarn is passed through tensioning device to control
the yarn tension.

Effects of tension on yarn and Yarn Package:

Too high tension:

•Can damage the yarn.

•Increase breakage rate of yarn.
•Change elongation properties of yarn.
•Can change molecular structure of yarn (in case of man-made fibre) which affects the
dye ability; and causes random variations in color shading.
•Can lead to hard yarn package.
Too low tension:

•Can lead to unstable packages which will not unwind cleanly.

•Loosely wound package have tendency to “slough off”.
Factors influences for selection of Tensioner:

• The device must be reliable to control uniformly in tension.

• It must be easily thread able.
• It must not introduce differences in twist.
• It must not be affected by wear.
• It must be easily adjustable.
• It must not be affected by the presence of oil and dirt.
• It must be capable of easy cleaning.
• The operating surface must be smooth.
• It must be inexpensive or cheap.
• It must be simple in design & operation.
• It must not cause damage for yarn.
Variation of tensioning device

A. According to working principle

• Capstan tensioner,
• Additive tensioner,
• Combined tensioner,
• Automatic tensioner.
Capstan tensioner
Additive tensioner:
Combined tensioner
Automatic tensioner:
B. According to the type of working
member acting on the yarn

1. Washer type tensioner.

2. Disc type tensioner.
3. Comb type tensioner.
4. Roller type tensioner.
5. Ball type tensioner.
6. Two – zone tensioner.
Auxiliary functions of winding:

•Creeling: Creeling is the placement of full

packages in position ready to be unwound as
a part of transfer operation.

•Piecing: Piecing is finding and connecting

of the ends on the packages. The connection
between the ends can be made by knotting,
adhesion or welding; but the former is by far
the most common.
•Doffing: Doffing is the removal of the
newly wound packages and the replacement
of these by empty packages which will receive
yarn during the transfer process.
Yarn guide:
In winding or unwinding, it is necessary to control the yarn path.
For controlling the yarn path, yarn guide is used.
There are mainly two types of yarn guide:
1.A yarn end is required for threading.

•Takes extra time in threading

•Low production
•More friction

2.A yarn end is not required for threading.

•Easy threading
•High production
Function
• To control the yarn path.
• Minimize yarn vibration.
• Reduce chance of balloon formation.
 Stop motion
Stop motion is active in case of
- Thread breakage
- Empty supply package i.e. yarn
supply is exhausted.
- Full delivery package i.e. yarn
package is completed. Other
interruption.
 Yarn Cleaner

Yarn cleaner is the device which is used to

remove the following faults of yarn in order to
increase the yarn quality and weaving efficiency.

The following faults removed by yarn cleaner:

• Thick and thin places in the yarn.
• Slubs and neps.
• Loose fibre.
• Foreign matters
 Types of yarn cleaner

• Metal sheet type/metal slit type ,

• Comb type,
• Ordinary metal slit type,
• Serrated blade type,
• Disc type,
• V- type.
Winding efficiency

• It is the percentage expression of the ratio of actual

production & calculated production.
• Winding efficiency = Actual production < Calculated
production.
• Efficiency =
Actual production /Calculated production *100
Related factors of winding efficiency

• Spindle / drum speed.

• Yarn count
• Yarn quality
• Worker efficiency
• Humidity
• Work load per worker
• Maintenance & over hauling
• Power failure
• Creeling time
• Doffing time
Balloon Theory

• The rotation applied to the departing

yarn during at high speed of the yarn
unwinding from a stationary spinning
cop, the yarn is thrown by centrifugal
force away from the cop axis &
circumscribes in space a plane is called
balloon.
• The shape of balloon depends on the
tension of the yarn at the unwinding
from cop.
Factors influence the size of
Balloon

• Yarn count
• Winding & unwinding speed
• Size and shape of the package
• Position of guide
• Lift of the package
Traverse Motion

By the help of motion when a dynamic part of a

machine moves in to & fro motion, then this
movement is called traverse motion. In the
package winding by the help of this motion yarn
is wound evenly in a package.

Traverse methods are mainly two types:

1. Reciprocating motion &
2. Rotating motion.
Reciprocating motion

By the help of this motion moving parts of a

machine is passed a fixed distance & with in a
several time it back its starting position.

This motion is performed in two mechanisms:

1. A single guide rod & cam for many winding
spindle.
2. A guide rod & cam for each spindle.
Reciprocating motion
Rotating Traverse motion

Rotating traverse motion is completed its

motion by the rotation of a grooved drum. On
the surface of drums there contains grooved
shape & yarn package is wound & rotates with
the surface contact of grooved drum.
Method of driving/ Driving of
winding packages:

• Surface contact driving,

• Directly package driving at constant rpm/speed.
• Directly package driving at variable rpm/speed.
Surface contact driving:
Directly package driving at constant
rpm/speed:
Directly package driving at variable rpm/speed.
Manual Machine
Features:
1. Knotting is done manually.
2. Creeling is done manually.
3. Low speed, so less production.
4. High labour cost.
5. Less initial cost.
6. Almost no fault removing capacity.
7. Not economic.
 Winding parameter
• Winding rate
• Winding on diameter
• Winding on surface
• Yarn traverse velocity
• Angle of wind
 Winding parameters

1. Winding rate:
Winding rate is defined as the amount of yarn to be
wound on the package per unit time i.e. the length of
yarn in meter wound on package per minute. Its unit
is m/min.
2. Winding on diameter:
The diameter of the package on which the winding is
done is called winding on diameter. It may vary
according to the package. Its unit is cm.
3. Winding on surface:
The place where winding is done according to the time is
called winding on surface. Its unit is m/min.
4. Traverse velocity:
Traverse velocity is defined as the amount of traverse
happened during winding per unit time. i.e. The length
of traverse in m/min is called traverse velocity, it is
denoted by Vt and its unit is m/min.
5. Surface velocity:
The rate of winding which is done on winding on diameter is
called surface velocity. It is denoted by Vs and its unit is
m/min.
6. Net winding velocity:
By dividing the traverse velocity with the sine value of
winding angle is called net winding velocity. It is called real
winding rate. It is denoted by Vr and its unit is m/min.
7. Angle of wind:
The angle contained between a warp of yarn on the surface
of a package and the diametrical plane of the package. Angle
of wind may vary with the traverse speed. No of coils in a
layer will be decreased with increasing the angle of wind. As
a result amount yarns will less on the package. It is denoted
by θ.
8. Coil angle:
The angle between the
horizontal axis and the
yarn is called coil angle. It
is denoted by β. Coil angle
may increased with
decreased the angle of
wind.
θ = Angle of wind.
β = Coil angle.
θ + β = 90°.
 Defects of Yarn
• The defects of yarn
• slub
• Nep
• Hairiness
• Gout or foreign matter
• irregular (Thick & thin place)
• Soiled or dirty yarn
• Snarl
• Twity or cockled yarn
• Trash
• Irregular twist
• Flying or adhering fibre
• Foreign fibre or wild fibre
• Immature or dead fibre
• Low twist or soft spun
•
Fault & Defect in winding

• Incorrect winding speed.

• Tension variation.
• Soft bobbin.
• Tight bobbin.
• No. of less removal of slubs, neps, dirt loose
fibres.
• Incorrect shape of packages.
• Too much knot in the yarn
• Excessive full bobbin.
 Fault & Defect in winding:

• Two end winding.

• Slack knots or knots with long tail.
• Overlapping.
• Mixing of yarn of difference linear density.
• Ribbon formation.
• Stitching or jail formation.
• Snarl.
• Wild yarn.
• Entanglement of yarn.