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Polar E PremiumAutomatic winder

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P o l a r E P r e m i u m

It is indeed recognized that the maximum level of automation on the winding process, is achieved by a direct link of the ring spinning frames to the winder.The advantages, already well known, through the continuous automatic transfer of the ring bobbins from one machine to the other are:• yarn quality of the wound package which is preserved

being the bobbins prepared and automatically doffed on the ring frames, without any operator handling or loading into separate boxes;

• higher efficiency on winder;• production output flow consistency and timed, as a

single machine;• minimization of winding room personnel.Most of customers select the link system solution whenever a new mill has to be set, or in alternative, whenever old ring spinning frames must be substituted.As a consequence, the real focus of Savio has been dedicated to propose an alternative solution, for all other mills where mainly existing ring frames are without automatic doffing, with the same winding efficiency of the link solution.Polar E Premium, has been designed to evenly process those yarn bobbins, whose formation is not originally “favourable” to reach that efficiency, keeping also the minimum number of operators.

A big step forward

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P o l a r E P r e m i u m

Hopper

The capacity has been increased thanks to the “double alternate” bobbin loading system on the peg.To achieve the full efficient peg loading rate, bobbins are mechanically spaced, bobbin shape identified by the“profile reader sensor” and properly oriented by the “cross shaped” rotating device.

The “profile reader sensor” detects also the empty tube and diverts it into a separate dedicated collecting box.The enhanced hopper capacity and efficiency, allows a loading rate to cover the winding heads up to 72 spindles.

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P o l a r E P r e m i u m

An efficient loading system requires that:• the oriented bobbins

before be loaded on the relevant peg, are cleaned from any flying attached yarn by an air suction located in each of the two coupling sleeves.

Peg feeding system

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P o l a r E P r e m i u m

End finder station

Particularly designed to handle bobbins with yarn reserve at the bottom of the tube (ring frames without automatic doffing), the end finder station is provided with a “knife bunch remover” in combination with an air suction blow for the cleaning; contemporaneously the yarn tail is introduced into

the tube upper hole to get the bobbin prepared to the winding head.All above described features of the Hopper/Peg feeding system/End finder station, transform the original “manual doffed” bobbin into a similar one used in the link system.

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P o l a r E P r e m i u m

The machine design has been focused on the lay out of the end finder station as follow:• the end finder stations,

are distributed along the machine frame and consequently allow the proper balanced distribution feeding capability to the whole machine. The machine can be regarded as a coupling of 2 o 3 single machines; the “centralized end finder system” cannot permit same even balancing.

End finder station layout

With this “balanced” solution, Polar E Premium can have up to max. n° 72 winding heads. Their positions being placed separately from the main bobbin/pegs belts flow, do not affect at all the efficiency of the system.Being front-side located, allow an easy intervention of the operator.

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P o l a r E P r e m i u m

A great help to ensure the highest efficiency of the winding process is given by the “Back up station” which shall take care of all bobbins rejected by the winding heads for different reasons:• Bad shaped bobbins.• Bobbin with yarn

remnants.• Bobbins with

technological alarms (off-standard quality yarn values).

Back up station

The station is able to prepare again the bobbin, with an high efficiency rate, because of the slow moving speed, and or to remove the faulty yarn portion, in case of a technological alarm.The diversified and specific movements are possible thanks to the “identification system” embedded on the machine and peg.The end result is also significant in terms of operator reduction, since no intervention is requested to the personnel.

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P o l a r E P r e m i u m

A traffic regulation is necessary for long machines; at this purpose identification tags placed in the peg trays allow:• automatic balancing

of feeding flow rate to yarn end finders: all the machine section and winding heads are equally fed and avoid idle spindles;

• traffic jams are also avoided;

• technological alarms are automatically removed;

• reduction of operator intervention.

• Fresh bobbin are loaded on L stations and conveyed to YF1, YF2, YF3.

• Rejected bobbins, tubes, technological alarms are discharged on the return belt.

• Tube with remnant yarns are cleaned by the tube cleaner and reinserted in the circuit.

• Rejected bobbins and technological alarms are conveyed to Back up station and reinserted in the circuit.

• Unrecoverable bobbins are parked on standby belt.

• Empty tubes are collected in a dedicated box. Also remnant bobbins and unrecoverable bobbin can be conveyed in separated boxes.

Intelligent bobbin distributionFresh bobbins Bobbins prepared

for winding process

Tube with remnant yarns

Empty tubes Unrecoverable bobbin

Yarn finders rejected bobbins

Spindles rejected bobbins

Technological alarm

1 Hopper2 Bobbing loading system (L stations)3 Tube clean station

4 Back up station5 End finder station (YF)

BOBBIN LOADER WINDING SPINDLES HEADSTOCK

2 21 3 4 5 5

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P o l a r E P r e m i u m

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P o l a r E P r e m i u m

Flexible cycleThanks to the individual motors and PC, the splicing cycle is automatically made, as per the actual requests of the splicing steps, improving, as consequence, the efficiency and production of the winder.

Consequently:• Greater productivity• Consistent package quality

(no presence of double yarns or yarn scrambling)

• Power and compressed air savings because unnecessary splicing cycle are avoided

• Minimum wear of the parts• Minimum yarn waste

Computer Aided TensionThe winding tension is detected continuously by the Tensor, which interacts with the yarn tensioner device, through the machine PC, in order to adjust the load on the yarn as required. The Tensor, being positioned just before the drum detects on line the real winding tension. The sensor does not have any movable parts and performs as “antiwrap system”.

Tensorflex (standard)In presence of elastomeric yarn blended with wool/cotton the tension values must be diversified during the package formation to ensure a perfect shape.

Flexible cycle

1 Drum2 Traverse3 Tension sensor TENSOR4 Waxing device5 Yarn tensioner

1 Independent movement of the package yarn suction nozzle

2 Independent movement of the splicer3 Independent movement of the bobbin

yarn suction nozze4 Independent movement of the yarn

tensioner device

1

2

3

4

5

PC

1

2

3

4

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P o l a r E P r e m i u m

Electronic anti patterning systemOn/Off modulation operates at critical diameters only.In the On/Off system, all the critical rates between package and drum diameters are memorized by the computer and consequently the drum is accelerated and decelerated, according to variable ramps, when there are possibility of ribboning formation. The system operates also during the acceleration after the splicing cycle.

Computer Aided Package®

(optional)It gives a perfect package, without ribboning and without changing the drum’s speed. The computer checks the distance between two consecutive layers and modify the ratio between package and drum diameters by micrometric variation in the inclination of the package holder and consequently in the driving point.

4

1

2

3

1

2

3

4

1 Drum speed2 Package holder position3 Ratio between package/drum

diameter drive in actual time4 Ribboning zone

1 Drum speed2 Package holder position3 Ratio between package/drum

diameter drive in actual time4 Ribboning zone

Anti patterning system

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P o l a r E P r e m i u m

All parameters of the winding process are controlled by theComputer:• yarn quality• package quality• production quality• control of all peripheral units• energy consumption.The Computer has a large touch screen and printer.The data are displayed in a descriptive and graphical form.Ethernet interface for connection to higher level information systems. The peripherals’ programme can be updated directly on the PC (also with remote loading).

Controlling the winding process

1 2 3 4 5 6 7 8 9 10 11 12

Spindle Monitoring SystemEach winding head is equipped with an alarm monitoring system.The operator is notified in real time of the ongoing alarm. Each spindle indicates technological as well as functional alarm.

1Yarn count alarmDifferent count2Package off standardMax n° of splicers in the package3Bobbin off standardMax n° of cleares cut in the bobbin4Yarn quality off standard (basic clearer) Max n° of neps - thin - thick places

5-8Examples of red ligths due to suctionpackage/bobbin/clearer splicer

Yarn quality off standard9Foreign fiber10Count variation11Moire12Pearl chain

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P o l a r E P r e m i u m

• The doffer trolley is electronically integrated with the winding heads and the machine PC.

• All the moving parts are driven by individual independent motors so to reduce the doffing cycle time to 13,5 seconds.

• The universal clamp is able to handle a certain different range of embty tubes conicity simultaneously without parts change.

• A new designed basket geometry to store different tubes conicity with no parts change, and to allow the easy tube colour recognition when different yarns are processed on same machine.

• The reserve yarn length is adjustable by the machine PC in order to meet any end user request.

• A fast patrolling speed up to 60 mt/min. in order to increase the doffing efficiency.

• The laser technology ensures the precise positioning of the doffer with the winding heads.

Doffer trolley Energy saving

Particular attention has been given to the suction system which represents the highest portion of the energy in the winding process.A special fan, with high performances aerodynamic blades in addition to the direct motor drive requests a minimum consumption of electric power.The motor fan, controlled by the machine PC through an inverter, adjusts its speed automatically in accordance with the actual working conditions and parameters.The yarn waste is collected in a separate filter box located in the machine headstock.The same fan provides also the vacuum to unload the travelling blower waste, once the blower reaches the proper discharge pipe also located in the headstock.The travelling blower waste is collected in a second separate filter box.In case of the “Dust collection system” device, the waste is unloaded in a third separated filter box.

Dust collection system (optional)A single suction unit for each head, located at the height of the balloon breaker, captures fibrils and dust produced when the bobbin is being unwound. Suction is created by a fan that serves two sections of heads. The impurities and dust are collected by a filter.

1

3

2

PC

1 Yarn waste filter box2 Dust removal system filter box3 Travelling blower filter box

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P o l a r E P r e m i u m

Air splicer: settings by machine PCAir splicer settings are completely centralised and consequently extremely quick and simple furthermore consistent uniformity of the yarn splicers on different winding heads is guaranteed.

Main application range: • Cotton 100% and blends• Cotton Compact yarns• Fancy yarns• Core yarns• Synthetic and artificial

yarns• Wool 100% an blends• Silk

Water splicer Duo Stage (optional)To increase the joint strength even with the compact yarns, mercerized and singed yarns, the splicing operation is made under vacuum while the water is injected (Duo-Stage). All the splicer parts are located in a “water proof” housing to avoid dangerous spray of water outside.

Main application range: • Cotton 100% coarse counts

(flat and fancy yarns)• Cotton 100% compact yarns• Mercerized/singed yarns• Elastomeric yarns• Two ply yarns• Open End yarns• Synthetic yarns• Linen yarns

TWINSPLICER(optional)The way the splice is prepared and made, ranks the Twinsplicer at the top among all other splicing devices. The splicer strength is always above 95% and the appearance same as the parent yarn. The splicer on compact yarns, beside the strength, needs an extremely good appearance not to create a visible defect on the finest fabrics. The Twinsplicer for core yarns preserves the elastomeric filament entirely inside the joints.

Main application range: • Cotton 100%• Cotton 100% Effect yarns• Compact Yarns• Elastomeric yarns• Cotton and blends

HEAT-SPLICER(optional)The consolidated experience on the splicer air technology in combination with the use of the heat, guarantees a final joint with excellent appearance, high and consistent strength even with, difficult yarn structures, different blended materials and high twisted yarns.

Main application range: • Carded wool coarse

counts• Mule spun yarn• High twist yarns• Wool 100% and blends

Total splicing system

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P o l a r E P r e m i u m

Computer Aided Density (optional)• Control of the package

load on the drum.• The package weight

increase is detected by the length metering and consequently the “electronic/pneumatic valve” is activated.

• Customized package load curve.

• The relevant parameters are programmable and stored in the machine PC.

The system is especially studied to process compact yarn producing soft packages for Dyeing (0.32 / 0.35 g/cm3).

Computer Aided Metering (optional)• The combination of the

laser detector beam with the package and drum speed sensor, is elaborated by the machine PC software.

• The system allow a metering high precision repetitiveness. ± 0,5%.

32 1PC

1 Piston 2 Electronic/p neumatic valve3 Cradle

21

PC

1 Package and drum speed sensor2 Laser detector signal

Computer Aided Density - Computer Aided Metering

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P o l a r E P r e m i u m

N

. HEA

DS

SE

CTIO

NS

LEN

GTH

6T 8T mm24 3 1 1553026 2 2 1617028 1 3 1681030 4 1745032 3 2 1819034 2 3 1883034 6 1893036 1 4 1947038 5 2011038 4 2 2021040 3 3 2085042 2 4 2149044 1 5 2213046 6 2277048 3 4 23510

N

. HEA

DS

SE

CTIO

NS

LEN

GTH

6T 8T mm24 2 2 1617026 1 3 1681028 4 1745030 3 2 1819032 2 3 1883032 6 1893034 5 1 1957036 4 2 2021038 3 3 2085040 2 4 2149042 1 5 2213044 6 2277046 3 4 2351048 2 5 2415048 6 2 2425050 5 3 2489052 4 4 2553060 8 2809064 6 4 2957070 3 7 3149072 2 8 32130

N

. HEA

DS

SE

CTIO

NS

LEN

GTH

6T 8T mm30 6 1893034 4 2 2021036 3 3 2085038 2 4 2149040 1 5 2213042 6 2277044 3 4 2351046 2 5 2415046 6 2 2425048 1 6 2479050 4 4 2553052 7 2 2627060 3 6 2883064 1 8 3011070 6 5 3223072 9 3 32970

With 1 end finder station With 2 end finder station With 3 end finder station Bobbin case

Automatic independent head winding machine, equipped with motors with individual speed adjustment and a flexible operating cycle.Models: POLAR E PREMIUM - independent winding machine.Headstock: right or left with respect to the working front.Frame: modular frame consisting of 6 or 8 head sections.Number of heads/machine: from a minimum of 24 to a maximum of 72 (see installation layout).Materials: natural, synthetic and blended staple yarns.Count range: from tex 286 to tex 4, from Ne 2 to Ne 147, from Nm 3.5 to Nm 250.Bobbin size: tube length: from 180 to 280 mm with a bobbin diameter of 32 to 72 mm. Length 350 mm upon request.Take-up: cross-wound packages: winding traverse 110, 152 mm, taper 0° ÷ 5°57’, maximum diameter 320 mm.Take-up speed: 400 ÷ 2200 m/min with continuous adjustment.WINDING uNITGrooved drums: in special, treated cast iron, directly controlled by the motor in axis.Electronic anti patterning system (standard).C.A.P.: electronic type with computerized control of the drum-package diameter ratio (optional).Package taper increase: 0°÷5°, mechanical type, electronic only with C.A.P. (optional).Axial displacement: with individual motor (optional).Electronic clearers: Uster, Loepfe with global and continuous yarn and splice control. Other manufacturers on request. Splicer: air type. Water, Twinsplicer, Heat-Splicer, knotters (optional).Yarn tensioner: a tension section, controlled by a single drive.Pre-clearer: Variable width.Tensor Waxing unit (optional) deflection type.Wax finished detection probe (optional).Booster: tension reducer.Meterage: standard or precision device (optional)Counterweight: standard pneumatic device or self-adjusting (optional)MACHINE BODYPackage conveyor belt: single lot towards the headstock. Belt cleaning system: for the belts of the machine body and bobbin loading station.Lighting along the machine (optional).Travelling blower/suction unit: programmable control frequency and unloading at machine headstock or centralized (optional).Dust removal system in the unwinding area consisting of single suction nozzles with a centralized dust collection box in the headstock (optional).COMPuTER (located in the section next to the bobbin loading station) Centralized electronic adjustments: machine data, processing parameters, air splicer working parameters, yarn tensioner pressure, V.S.S., electronic modulation.Setting, collecting and displaying production data: of winding units, bobbin loading station, doffing trolley, display of the peripherals’ alarms.HEADSTOCKCentralized pneumatic adjustments: package cradle counterweight, splicer air pressure.Machine control panelPACKAGE uNLOADING SYSTEMDoffing trolley: automatic package doffing, insertion of the cone on the spindle head, cycle time: 13,5 seconds.Double doffing trolley (optional).Cones feeding: individual cradle on each winding unit.Centralized cone magazine (optional).Double centralized magazine (optional).BOBBIN LOADING STATIONBobbin tail pick-up station: modular up to 3 stations, capacity per station 1,440 cycles/hour. Tube cleaner: capacity 240 tubes/hour (optional).BOBBIN FEEDING Loading: tipper located along the machine’s axis and vibration system to thin out bobbins. Maximum capacity 3,000 cycles/hour.

Overall dimensions and installation layoutTechnical summary

MACHINE LENGTH

2932B1135

1810

2278 2660 (8T) 2020 (6T) 1600

1275

620 620352

925

(SM

) - 2

885

(SBB

) - 2

860

(E)

H

2684

3195

(SM

) - 3

150

(SBB

)

MAx. 260 KG

(L)max. 1330

min. 550max. 840

min. 700max. 1240

We reserve the right to modify the characteristics of the machines described herein without prior notice. The data given in this brochure are not intended as a guarantee. Savio machines are equipped with safety devices in compliance with existing regulations.

L B H1020 660 29901100 720 30601200 790 31501330 890 3260

SM = SAvIO MAGITEx - SBB = SAvIO BELT BLOWER - E = ELECTROjET

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P o l a r E P r e m i u m

SAvIO MACCHINE TESSILI S.P.A.33170 PORDENONE (Italy)Via Udine, 105Tel. +39 0434 3971Fax +39 0434 397599E-mail: order@saviospa.itwww.saviospa.com

SAvIO INDIA LTD.Nallattipalayam, Tamaraikulam - PostPollachi, Coimbatore - 642109Tamil Nadu, IndiaTel. +91 4259 304555Fax +91 4259304567E-mail: mail@savioindia.in

SAvIO (SHANDONG)TExTILE MACHINERY CO., LTD.No.6 Torch Industry Park, No. 2166 Chongwen Dadao,High&New Tech IndustryDevelopment Zone, Jining,Shandong, P.R. China 272000Tel. +86 0537 2395206/101Fax +86 0537 2395216 E-mail: info@saviochina.com

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