Abstract
A large amount of work has already been done on the development of spun yarn technology. The following article especially evaluates the latest inventions in its production, such as the twisting system built on superconducting technology in a ring spinning system and the idea of manufacturing cluster-spun composite yarn. These technologies have very high potential and have not yet been used in the industrial sector.
Introduction
Spun-yarn products and processes have undergone various modifications to existing techniques and have also seen significant new developments. During the spinning process, twisting plays an active role in transmitting tensile strength. The resistance between the ring and the traveler is the major flaw in this technology. It generates heat at a very high speed, which results in limited productivity. This resistance between the traveler and the ring is remarkably reduced through the implementation of a magnetic-bearing system based on superconducting technology. It completely replaces the present ring-and-traveler system of this machine. Cluster-spun yarn is thus a new concept in the production of composite yarn. In this concept, a slotted roller is used with polyester multifilament and a mixture of cotton fiber. The slipperiness of staple fibers relative to the filaments is reduced in this yarn compared with core-spun composite yarns.
Twisting Mechanism
A. Background
Ring spinning is used to a high degree in the short-staple spinning process. The superiority of this process remains over alternative spinning technologies, for example, air-jet and rotor spinning. The ring-and-traveler combination inserts twist and winds the yarn. However, the main drawback of the old system is the resistance between the two components. A large amount of heat is generated at greater speeds, which results in decreased production. This drawback is reduced through a magnetic-bearing system based on superconducting technology by replacing the present ring-and-traveler system. It consists of a circular superconductor and a permanent magnet ring.
B. The Functionality Of Superconducting Magnet Bearing
The superconducting magnetic bearing is a combined system involving, for example, a permanent magnet and high-temperature superconductor (HTSC) components (Mahmud Hossain, 2014).
These bearings are self-stabilizing because they remain entirely passive devices without any essential need for position sensing and regulators. For this reason, they are wear-free, do not require redundant sensor and control elements, have very high reliability, and have no EMC (electromagnetic compatibility) problems (Mahmud Hossain, 2014).
Below the normal temperature, when the superconductor is cooled down, the permanent magnet ring levitates and rotates freely above the superconductor ring according to the principles of superconductivity and flux pinning. Hence, the SMB assures friction-free operation during spinning, allows a considerably higher speed, and drastically increases the production rate. After investigation of the SMB system, the yarn features were found to be similar to those of conventional ring-spun yarn.
C. Conclusion
Over the last 150 years, many twisting mechanisms have been developed to achieve a very high rate of production. Spindle development, smaller rotating-ring dimensions, automation, etc., were among the most important developments of this period. Most importantly, this bearing system has a straightforward construction, unlike other systems such as active magnetic bearings. Also, this friction-free superconducting magnetic bearing system has very high potential to replace the present traveler system. However, a little more optimization is required in the size and weight of the permanent magnet. A theoretical method is required for predicting yarn tension, balloon formation, permanent-magnet weight, etc., while taking the superconducting magnetic bearing system into account. Because there is no friction, there is a possibility that the yarn can be spun at twice the speed of a ring-spinning machine. Many researchers have previously established mathematical models for the ring-spinning process. Thus, this system, i.e., SMB, represents a development in the yarn-twisting mechanism that eliminates the resistance of the ring-and-traveler system in the present ring-spinning machine.
Cluster-Spun Yarn – An Innovation In Composite Yarn Spinning
A. Background
Researchers have placed considerable emphasis on improvements in composite-yarn spinning procedures. In this method, a unique structure is formed through the combination of continuous filament yarn and staple fibers. Various spinning methods produce composite yarns, for example, ring, air-jet, friction, and rotor spinning, among which the most conventional is the modified ring-spinning method. It has two components, i.e., staple fibers and filament. They form the core-and-sheath structure of the yarn.
The major problem with composite yarns is the slippage of staple fibers relative to the filament. A high level of twist is applied to build consistency between the core component and the sheath. However, this increases the cost of production and reduces the speed of production as well. To address this issue, a new concept of cluster-spun yarn was developed. It consists of polyester multifilament drawn by a slotted roller and staple fibers that form the principal component. Some physical features of cluster-spun and core-spun yarn were evaluated through SEM, i.e., scanning electron microscopy (Mahmud Hossain, 2014). Image-processing and microscopic methods are used to study the distribution of fibers in cross-sections of sample yarns and to investigate their tenacity and elongation at break (Mahmud Hossain, 2014).
B. Cluster Spun-Yarn Properties
Core-spun yarns have lower tenacity and elongation than cluster-spun yarns, which means that clustering influences yarn properties and structure for the following reasons:
- The mixture of cotton fiber and polyester filament provides greater friction and cohesion between fibers.
- It decreases the tendency of staple fibers to slip relative to the filament, resulting in increased fiber migration in the yarn.
- Cluster-spun yarns have a clearer appearance than core-spun yarns, and the structure of cluster-spun yarn is packed more tightly than that of core-spun yarn.
C. Conclusions
An innovative method of manufacturing composite yarn, called cluster spinning, produces a twisted yarn consisting of cotton fibers and polyester multifilament separated by using a slotted roller.
A slotted roller has grooves that divide the multifilament into two or more substrands, which produce cluster-spun yarns.
The differences in the internal and mechanical structures of cluster-spun yarn produce better yarn properties. Ultimately, this improves yarn properties and reduces the tendency of staple fibers to slip relative to the filament. Also, a significant increase in friction and cohesion produces an evenly and tightly blended mixture of polyester filaments and staple fibers in cluster-spun yarn. Additionally, a lower twist is required for the production of quality yarn. As a whole, cluster-spun yarn has high potential to play a vital role in the commercial application of composite-yarn spinning in the near future.
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