c

  or open-end spinning is a technology for creating yarn without using a spindle.

It was
invented and developed inCzechoslovakia in Výzkumný ústav bavlnářský / Cotton Researching Institute
in Ústí nad Orlicí in the year 1963. It is also known as 

  or    . The principal
behind open end spinning is similar to that of a clothes dryer spinning full of sheets. If you could open the
door and pull out a sheet, it would spin together as you pulled it out. Sliver from the card goes into the
rotor, is spun into yarn and comes out, wrapped up on a bobbin, all ready to go to the next step. There is
no roving stage or re-packaging on an auto-coner. This system is much less labour intensive and faster
than ring spinning with rotor speeds up to 140,000rpm. The Rotor design is the key to the operation of the
open-ended spiners. Each type of fiber may require a different rotor design for optimum product quality
and processing speed.

The first open end machines in the UK, were placed under great secrecy, by Courtaulds into Maple Mill,
Oldham in 1967.

The disadvantage of open-end spinning is that it is limited to coarse counts, consequently cloth made
from open-end yarn having a 'fuzzier' feel and poorer wear resistance.

R


[hide]

ï History

‰ Characteristics

¢ References

K Bibliography

[edit]History

The global demand for Fibre is huge. Converting raw fibre to yarn is a complicated process. Many
manufacturers compete to provide the spinning machines that are essential to meeting the demand by
delivering increases in spinning productivity and additional improvements in yarn quality. Over the past
three centuries spinning technology has been continuously improved through thousands of minor
innovations, and occasional major advances that have collectively increased the quality and lowered the
cost of producing yarn dramatically.

Major technology advances have included:

 Hand spinning,
 Mule spinning
 Ring spinning
 Rotor spinning
 Dref Friction Spinning
 Open-End spinning.
*evelopment stages of Open-end Spinning
ï ¢
Berthelsen developed a relatively perfect open end.
ï  Czech KS‰ rotor spinning machine was introduced at ¢ rotor rpm.
ï 
Improved B*‰ with Gï Rieter were presented with first mill of OE coming under production
There was a considerable increase in machine manufacturer and newer and improved
ï
ï
ï
 version of machines were launched with increased speed at ï rpm .

Also witnessed first automated machine from Sussen equipped with Spincat and Cleancat which opened
ï

up the industrial rotor spinning breakthrough.
ï

Witnessed Schlafhorst with Autocoro machines which made a mark in open end market.

The number of manufacturers who can successfully compete has been reduced as the technical
complexity of the spinning machines has increased. However, there are many competent companies
serving the global market for spinning machines who continue to pursue innovative ways to increase
spinning productivity and yarn quality.

[edit]Characteristics

A good Open-end machine should have,

 Higher productivity
Higher Productivity:- This is a major criteria as productivity reduces the cost of manufacturing.
The O.E machines which are now in market boasts of many a basic needs like, longer length of
machine, higher speeds, able to process coarser hank, fewer changes for Count, easy access to
parts (less downtime for cleaning), longer production time between cleaning schedules,
computerized controls for less power consumption and lower downtime and complete report
generation giving leads to problem area are some points to discuss.

 high content sliver cans (up to 18´)

Large Sliver Can:- In early days large machines were equipped with less distance between
Rotors (Gauge of machine). This led to creeling of very small cans, which required frequent can
changes. Each can change requires a break in the yarn. All major manufacturers currently allow
cans up to 18´ diameter leading to less breakage, less joining of yarn, hence better quality and
higher productivity. Originally round cans were used. Rectangular cans are used because they
double sliver capacity in the same sliver can footprint.
  Larger packages of yarn (4 to 5 kg)
Large Final Package:- The final package size has continued to increase. The final package size is
important because it reduces tube change frequency and thus reduces idle time for creeling.
Current yarn packages typically weigh 4 to 5 kgs. The Savio Super Spinner 3000 currently has
the largest package size at 6kgs.

 Less power consumption

Less Power Consumption:- Using individual motors and electronic controls for each of the various
drives of the machine maximize energy efficiency and minimizes downtime.

 Automation
Automation:- All spinning machines, whether ring or open end, need yarn joining to repair breaks
or start new sliver cans. Joining the yarn has historically been a labor intensive activity and a
source of quality defects. Autopiecing units are robots that automate this process. Market leaders
like Schlafhorst, Rieter, Savio have machines that incorporate good quality autopiecers and
autodoffing. This automation leads to less material handling costs and helps improve quality of
the final product.

 Flexibility of spinning components

Flexibility of spinning component:- Many vendors are offering machines that can be programmed
to produce many different types of yarns. The ability to rapidly change production results in the
flexibility to serve multiple markets. A contemporary spinning mill should be able to produce a
range of products: denim, knitting, towels, structured fabrics, construction fabrics and various
other products like core spun, multi count etc.

 Handling count range.

Handling count range:- Machines need to be easily programmed to spin yarns from 4sNe to
60sNe. This ability allows a single machine to produce yarns that cater to many different end user
requirements.
[edit]References

'



 
  

Main features of these machine are :-.

‡

1. Rotor speeds up to 130000 rpm with aero air bearings.

2. Delivery speeds up to 200 m/min.
3. Up to 280 spinning positions.
4. Gauge of 245mm for large round cans & rectangular cans.
5. Count range from 125 tex to 10 tex [ne 5 to 60].
6. Spinning unit for drafts up to 400.
7. Complete range of spinning elements for all types of rotor yarns.
8. Rotor diameter from 30 to 56 mm.
9. Efficient trash removal.
10. Syncro top technology for yarn-like Piecings.
11. Modern compressed air technology for rotor cleaning.
12. Redipac package quality for cylindrical & conical cross-wound packages [ 2 degrees , 3
degrees 51 minutes , 4 degrees 20 minutes].
13. Package weight up to 5 kg.
14. Package diameter up to 340 mm.
15. Infinitely variable drives for draft & twist.
16. Integrated automation for rotor cleaning, piecing, package change , batch change,
empty tube feeding.
17. Package & batch change without starter bobbins.
18. Package removal systems :- a] package lift. B] servopac. C] Servocone.
19. Comprehensive function & quality monitoring systems.
20. Cubican system for fully automatic can handling.
21. Extremely low noise emission.

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B] effective fibre length = ¢‰ mm.;
C] fibre breaking length = ‰-‰ km. ;
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Rotor Speed
Rotor Diameter (mm) Staple Length (mm) Linear Density (Tex)
(1000RPM)
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y ‡The doubling effect in the rotor after the complete separation down to individual fibres
is well known to result in a homogenous fibre distribution in the yarn cross section. This
situation is ideal for blending .
y ‡Therefore it provides an opportunity, by correct use of the rotor spinning process , to
produce polyester-fibre-cotton blended-fibre yarns not only more economically but also
with improved yarn quality.
y ‡ However some of the properties of man-made fibres can impose limitations on the use
of the rotor spinning process.
y ‡ In the first place , the dielectric properties of the fibres themselves may cause a build
up of static charges on the fibres during processing.
y ‡ Secondly, the surface of the fibres, especially that of dull or matt fibres , may become
an aggressive agent , damaging the machine parts that are liable to come into contact
with fibres during spinning.
y ‡In addition, it is not only a low fibre strength but also fibre brittleness that is partly
responsible for fibre damage, shortening , & the consequent rotor dust accumulation.
y ƒ

 


 





y ±Staple length:-.
More the staple length more will be the fibre friction & more difficulty for opening roller to
separate fibres.
‡This will lead to fibre shortening & then rotor fauling.
‡ Hence comparitively ( comparing with ring spinning) shoter staple lengths are used[
for polyester fibres 32mm.].
y ±Fibre fineness:-.
‡ The advantage of finer fibres is that, while maintaining the minimum number of fibres
in the cross section, one can raise the fine-yarn count limit for rotor spun yarn
considerably.
‡ Further advantages are the ability to reduce yarn twist & increase breaking tenacity.
‡ But use of extremly fine fibres may lead to fibre damages during preparation especially
during carding.[Ideal linear density =1.5 denier].
y ±Fibre crimp:-.
 ‡Highly crimped fibres have greater resistance to extraction from the sliver by opening
roller,which leads to fibre damage & rotor fauling.
‡ Also they do not flow smoothly in the duct between the opening roller & the rotor;
Furthermore they do not lie in a compact mass in the `v` of the rotor groove.
‡While the fibres with low crimp levels give higher yarn strength, fewer yarn defects & a
reduced number of ends down.
‡ But the fibres with too low crimp level or performance will have poor card-web
cohesion & result in a poorly drawn sliver.
y ±Tenacity :-.
‡ High tenacity fibres are reported to perform better than lower-strength versions
because they minimize the strength loss of open end spun yarns, suffer less breakage
& therefore produce fewer rotor deposits.
y ±Relative humidity & temperature:-.
‡Relative humidity should be between 50-55% & temperature should not be lower than
23 deg. Celsius.
y ±Sliver preparation :-.
y ‡Rotor spinning parameters :-.
y ±Combed sliver do not much improve the yarn quality as compared to the carded sliver.
y ± Blending can be done by flock-blending & draft sliver blending methods.
y ±However, with draft-sliver blending, even after the second passage of drawing, the
sliver is still basically in a stripe form.
y ± If the sliver blending is used, autolevelling should be therefore carried out at the card
with two or three drawframe passages prior to spinning.
y ±1] opening roller parameters :-
m .‡Inclination of teeth of clothing = 90 degrees, the tooth height = 1.2 mm. , THE
DISTANCE BETWEEN THE TEETH = 4 mm. , Density of teethes =14 teethes
per square centimeter. , Opening roller speed= 6000-7000rpm.
y ± 2] rotor parameters :-.
m ‡Twist factors = 120 - 140;
m ‡Spinning tension must not exceed 60 % of the yarn strength ;
m ‡Ratio of rotor diameter to fibre length should not be less than 1;
m ‡Smaller rotor diameters require higher rotor twist;
m ‡Higher rotor speeds leads to a steep rise in yarn tension, & resulting yarn friction
against the doffing tube may cause localized melting of synthetic fibres.
y ± 3] Doffing tube parameters :-.
m Smooth doffing tubes are recommended in preference to the notched type in order to
keep stresses on the yarn within acceptable limits
Ä



  

y ‡Multicomponent yarns consisting of two or more different yarns have been produced on
modified rotor units , the aim being to spin a final yarn possessing all the desirable properties of
the individual component yarns.
y ‡ Several problems have prevented the different techniques studied from progressing to at least
the prototype stage.
y ‡The major & the most common difficulty is the high yarn breakage rate that occurs in the rotor.
The frequency of yarn breaks is unacceptably high even when continuous-filament yarn is used
as one component.
y ‡Not only is the yarn-breakage rate a problem, but the resultant yarn quality is also usually poor,
since it is extremely difficult to achieve proper tension control of the yarn component yarns
during spinning.
y ‡With rotor spinning system, the Multicomponent yarn has a construction in which the staple
fibre component is positioned at the centre & a continuous filament yarn is wrapped around it.
y ‡The resulting yarn is claimed to possess the desirable properties of both spun yarn &
continuous filament yarn.
y ‡It is reported to have a good handle , similar to that of spun staple fibre yarns, & also an
excellent resistance to abrasion as a result of continuous-filament wrapper.
y ‡ The yarn is claimed to be suitable for use in fabrics intended to be made into outer garments.
Ä 
Ä



y ‡Fancy slub yarns can be produced on rotor spinning machines by varying the draft briefly in the
sliver feed & opening roller system to give deliberately thick places in the yarn.
y ‡In an alternative method, patented by pittman, slubs or thick & thin places are produced
through twist variations by changing the delivery speed of the yarn as it leaves the rotor.
y ‡The method produces a unique slub yarn, which has a portion of high twist adjacent to the slub
in theyarn, which has lower yarn twist.
y ‡A second technique based on twist variations as shown in fig. 1.
y ‡The design of the system is such that the roving [12] is spun by rotor housed in [14]. The yarn
leaves through doffing tube [18] & passes through rollers [21, 23] to be wound onto the bobbin
[28].
y ‡A lever [20] with a roller at its end [19] swings randomly up & down to lengthen & shorten the
yarn between the doff tube [18] & rollers [ 21, 23], which thereby speeds up & slows down the
yarn leaving the doff tube.
´
 

y ‡Turns /Metre [Tpm] =rotor rpm {N} / yarn-delivery rate{ V Metre/min. }=N / v.
y ‡Turns / metre [tpm] = twist multiplier * 100 / [tex]^1/2 = 100k / t ^ 1/2.
y ‡Yarn delivery rate = N / Tpm =N [T^1/2] / [100k] m/min.
y ‡Productions / spinning unit [P] is directly proportional to the yarn delivery rate & linear density
[tex] I.E. P= 60vt/1000=0.06vt therefore P={ n[t^1/2] /100k} 0.06t = 0.0006n [T ^3/2] /K gm/hrs.
y ‡Thus , the production per spinning unit of an open end spinning machine {at 100% efficiency} is
determined only by the rotor speed , which is normally fixed for a given design , & the yarn linear density
& twist .