Winding Machine

 

Basic Winding Process

Working Principles and Calculations of Winding Machines

 Working Principle of Cone Winding Machine

The cone winding machine is designed to wind yarn onto conical bobbins (cones) for further processing in weaving or knitting.

Working Principle:

1. Yarn Feeding: The yarn is drawn from the supply package (ring bobbin or hank).

2. Tensioning: A tension device ensures uniform yarn tension during winding.

3. Traversing Mechanism: A cam or grooved drum guides the yarn to form a stable conical package.

4. Winding: The yarn is wound onto the cone with a precise winding angle to prevent slippage.

5. Package Formation: The machine ensures uniform density and proper build-up of the cone.

Applications:

• Used in textile mills for producing cones for warping, knitting, and weaving.

Working Principle of Pirn Winding Machine

A pirn winding machine is used to wind weft yarn onto pirns for shuttle looms.

Working Principle:

1. Yarn Supply: Yarn is fed from a cop or cone.

2. Tension Control: A tensioner maintains consistent yarn tension.

3. Pirn Mounting: The empty pirn is mounted on a spindle.

4. Reciprocating Motion: A traverse guide moves back and forth to distribute yarn evenly.

5. Winding: The pirn rotates while the yarn is wound in layers to ensure smooth unwinding during weaving.

Applications:

• Primarily used in traditional shuttle looms for weaving.

Working Principle of Cop Winding Machine

A cop winding machine transfers yarn from a larger package to smaller cops for use in shuttle weaving.

Working Principle:

1. Yarn Unwinding: Yarn is unwound from the supply bobbin.

2. Tensioning: A tension device ensures uniform winding.

3. Cop Mounting: The empty cop is placed on a spindle.

4. Reciprocating Guide: A traverse mechanism ensures even distribution of yarn.

5. Winding: The cop rotates while yarn is wound in a precise pattern.

Applications:

• Used in textile mills to prepare cops for shuttle looms.

Working Principle of Auto-Coner (Automatic Cone Winding Machine)

The auto-coner is an advanced winding machine that automates cone winding with minimal manual intervention.

Working Principle:

1. Automatic Doffing: Detects full cones and replaces them with empty tubes automatically.

2. Yarn Clearing: Electronic yarn clearers detect and remove defects (slubs, thick/thin places).

3. Splicing: Broken yarns are spliced (knotted or welded) for continuous winding.

4. Tension Control: Precision tensioners ensure uniform winding.

5. Winding Drum: A grooved drum controls the winding speed and package density.

Advantages:

• High-speed winding

• Improved yarn quality

• Reduced labor cost

Production and Efficiency Calculation of Winding

Production Calculation:

The production of a winding machine depends on:

• Winding Speed (m/min)

• Number of Drums/Spindles

• Machine Efficiency (%)

Formula:

$$\text{Production (kg/hr)}=\frac{\text{Winding Speed (m/min)}\times 60\times \text{No. of Spindles}\times \text{Yarn Count (Ne)}\times \text{Efficiency}}{768.1\times 1000}$$

Example Calculation:

• Winding Speed = 1000 m/min

• Number of Spindles = 60

• Yarn Count = 30 Ne

• Efficiency = 85%

$$\text{Production}=\frac{1000\times 60\times 60\times 30\times 0.85}{768.1\times 1000}=119.5\text{kg/hr}$$

Efficiency Calculation:

$$\text{Efficiency (\%)}=\left(\frac{\text{Actual Production}}{\text{Theoretical Maximum Production}}\right)\times 100$$

Factors Affecting Efficiency:

• Machine stoppages (yarn breaks, doffing time)

• Maintenance and operator skill