Welcome to our project presentation

Welcome to the project presentation

Project TitleImpact of different clearing limits of yarn clearer on yarn quality and productivity

Conducted by

NASIF MAHMOOD11.02.06.019

FAHAD HALIM11.02.06.041

Introduction

IntroductionYarn clearing is a part of the yarn winding. The device which is used to remove faults (thick places, thin places, foreign matter etc.) from the yarn is known as yarn clearer.

ObjectivesThis project represents the comparative study of yarn quality and productivity due to different yarn clearer settings of winding machine

Studied different yarn clearer settingsAnalyzed various types of yarn faultsObserved number of yarn cuts due to different yarn clearer settings Compared yarn quality and characteristics before and after windingStudied the effect of different yarn clearer settings on winding productivity and wastage generationWhat we did in the project

Literature review

Why is yarn clearer used?

Types of yarn clearerMechanical type1. Conventional blunt type2. Serrated blade typeElectronic type1. Capacitance type2. Optical type

The capacitive measuring principle

1. Electrode 2. Electric field 3. Alternating voltage4. Yarn5. Electrical signal

The optical measuring principle

1. Infrared light source 2. Diffuser3. Photocell4. Yarn 5. Electric signal

Types of faults removed by yarn clearer1. Thick places2. Thin places 3. Count variations4. Foreign fibers5. Periodic yarn faults

Seldom occurring faults and frequently occurring faults

Definition of the yarn body

Yarn body defines the nominal yarn with its tolerable, frequent yarn faults. The green shaded area represents the yarn body.

Clearing limitThe clearing limit defines the threshold level for the yarn faults, beyond which the cutter is activated to remove the yarn fault.i. Sensitivity This determines the activating limit for the fault cross sectional size.ii. Reference length This defines the length of the yarn over which the fault cross-section is to be measured.

REFERENCE LENGTH

SENSITIVITY

Classification Matrix

Winding

Extraction of all disturbing yarn faults. Manufacture of cones.Waxing of the yarn. Production of yarn with minimum number of splice.

Different parts of winding unit

Factors influencing winding productivity

SplicingThe process of piecing of two yarn endsresulting from yarn breaks, removal of a yarn defect, or due to the end of the supply package is called splicing.

Pneumatic splicer

Splicing operation

Material and Method

Fibre used :The property of the raw cotton determines the processing parameters of the spinning machinery and the quality of final yarn. For the current experiment, we have used 100% Mali cotton.

Flow chart of the experimental process:

Machine used

Process parameters

300 ring cops were selectedThey were divided into 3 groups each containing 100 cops 3 drums of winding machine were selected3 different yarn clearer settings were chosen for Uster Quantum 2 Cut data were collected for each settings Production and wastage of winding machine were calculatedStrengths of splice were measured with Tecloch Then yarn samples were taken to Quality Control Department for offline testing

Working procedure

Uster Quantum 2ManufacturerModel No.IMK type: Zellweger Uster, Switzerland: SE 617: IMK-C15-F23

Sample 1Close settingSample 2Moderate settingSample 3Wide setting

Thick place%cmNSLH1H2H3H4H5H620012020100908060450.00.01.220.01.52.55.015300.0

Sample 1 (close setting)

Thin place-%cmTH1H2H3H4H5H63042383528 260.01235720300.0

Continued.

Scatter plot for sample 1

Thick place%cmNSLH1H2H3H4H5H62501804014010075350.00.00.01.52034.26.5320.00.0

Sample 2 (moderate setting)

Thin places-%cmTH1H2H3H4H5H630423633260016.03.06.011.032.00.00.0

Continued.

Scatter plot for sample 2

Thick place%cmNSLH1H2H3H4H5H650030090000000010900.00.00.00.00.00.0

Sample 3 (wide setting)

Thin places%cmTH1H2H3H4H5H645706040300045101828100.00.0

Continued.

Scatter plot for sample 3

Graphical Representation

Comparison of number of yarn fault cuts per 100 km (N, S, L, T) of samples for different yarn clearer settings:Number of yarn cuts

Comparison of mass variation (CVm%) of ring yarn and cone yarn of different yarn clearer settings:

Comparison of thick place(+50%) of ring yarn and cone yarn of different yarn clearer settings:

Comparison of thin place (-50%) of ring yarn and cone yarn of different yarn clearer settings:Thin place(-50%)Ring yarnSample-1Sample-2

Comparison of neps of ring yarn and cone yarn of different yarn clearer settings:

Comparison of IPI of ring yarn and cone yarn of different yarn clearer settings:IPI

Retained splice strength (RSS %)

Comparison between spliced yarn strength and parent yarn strength

Comparison of CSP of ring yarn and cone yarn of different yarn clearer settings:

Comparison of SEF% of cone yarn of different yarn clearer settings:

Comparison of productivity of cone yarn of different yarn clearer settings:

Comparison of wastage% of autoconer due to different yarn clearer settings:Wastage%

Key findingsIt was observed that sample-1 has the highest number of yarn fault cuts than sample-2 and sample-3 where sample-3 showed lowest number of yarn fault cuts. On the other hand number of yarn fault cuts for sample-2 was found in between sample-1 and sample-3.Both sample-1 and sample-3 showed higher CVm% than ring yarn where sample-1 was the highest. On the other hand sample-2 had lower CVm% than that from sample-1, sample-3 and ring yarn.It was observed that both sample-1 and sample-3 had higher IPI value than ring yarn where sample-2 showed no significant change of IPI value than that from ring yarn.CSP values for all samples was observed lower than that from ring yarn where sample-1 was lowest, sample-2 had higher value than sample-1 but sample-3 had highest CSP value among all these samples.

ContinuedSpindle efficiency% for sample-3 was observed highest and for sample-1 it was lowest where spindle efficiency% for sample-2 was in between sample-1 and sample-3.In case of production it was observed that sample-3 had the highest productivity and for sample-1 it was lowest. Alternatively productivity for sample-2 was found in between sample-1 and sample-3.In case of waste generation it was observed that sample-1 had the highest waste generation% and for sample-3 it was lowest where waste generation% for sample-2 was in between sample-1 and sample-3.

LimitationsThe hairiness module of Uster Tester-5 was disabled. Therefore, we could not observe hairiness properties of yarn before and after winding.There was no single yarn strength tester as a result we could not observe tenacity, breaking elongation of yarn before and after winding. The method used for calculating waste% was not accurate enough since it was not possible to collect waste data individually from three drums. Thus waste% data was calculated based on data of winding waste produced per shift due to cuts.Only three yarn clearer settings were used in this project due to unwillingness of factory authority to spare more time, material and machine. So, it was not possible to observe intermediate yarn clearer settings which would have helped to understand more effectively about the consequence of clearing limits on different yarn properties and productivity.

ConclusionBased on experiments and observations conducted in this project work, it can be concluded that clearing limit of yarn clearer has a significant impact on yarn quality and productivity. Yarn clearer setting, too close or too wide, had adverse effect on yarn quality. If the yarn clearer setting is too close, the clearing limit will cut across the yarn body causing excessive cuts than normal. Again if clearing limit is too wide it will allow faults in ring yarn to pass freely to cone. The number of cuts during winding operation was directly affected by sensitivity of yarn clearer. Higher number of cuts caused drop in spindle efficiency and productivity with increase in waste generation. It can be concluded that the appropriate clearer setting is crucial for optimum yarn quality and productivity level and is needed to be determined by trial and error method.

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