No. 73/2002US $ 5.–

SPININNOVATIONT H E M A G A Z I N E F O RS P I N N I N G M I L L S

Three Yearsof Experience withSUESSENEliTeQCompactSet

Solutions for Open-EndRotor Spinning

Company Profiles:· Harriet & Henderson, USA· Textilgruppe Hof, Germany

Cotton Inc., USA,and Compact Spinning

2

SPINNOVATION No. 7

CONTENTS

Three Years of Practical Experience with theEliTeQCompactSet in Short-Staple Spinning 3

Solutions for Open-End Rotor Spinning . . .– Polyester and MIMA Navels . . .– Cotton Yarns and GSQ Rotors . . . 2

Harriet & Henderson Yarns, Inc., NC, USAInterview with Jim Booterbaugh and Rick Barton 5

Cotton Inc., USA, in favor of theSUESSEN EliTeQCompactSet 8

Portrait of ”Textilgruppe Hof”, Germany, and theirExperience with the SUESSEN Modernizationof Autocoro Rotor Spinning Machines 2

Carbon Fiber Traverse Rod in Modernizationof Autocoro Rotor Spinning Machines 24

News 27

ImpressumNo. 7 – March 2002 · Price: US-$ 5.–Publication: twice a yearInformation & Advertising Contact:Spinnovation, GermanyFax (++ 49) 762 5-367 · www.suessen.comPublished by Spindelfabrik SuessenPostfach 3 20, 73075 SüssenFederal Republic of GermanyEditor in Chief: Peter StahleckerTitle registeredQ at German Patent OfficeCopyright q 2002Reprint of articles with reference permitted –Voucher copies desiredSpindelfabrik SuessenAll rights reserved –

Front Cover:EliTeQCompactSet – The Next Generation

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3

SPINNOVATION No. 7

Three Years of Practical Experience with theEliTeQCompactSet in Short-Staple Spinning

. Preliminary Remarks

About three years ago, the EliTeQ

CompactSet for compacting ring

yarns was introduced world-wide and

since then more than 250,000 spin-

dles have been installed in the spin-

ning industry under most different

conditions. Undoubtedly, this spinning

process, which follows the drafting

system of the ring spinning frame,

represents the first really important

step in the development of ring spin-

ning since the introduction of direct

link between ring frame and winder.

As the spinning triangle is eliminated,

which until now is the weakest point in

ring spinning apart from the ring/trav-

eller system, new and brilliant pros-

pects are opened for this old techni-

que, often reputed to be dead. This is

not a short-lived fashion mania to

satisfy the demand for yarns with

reduced hairiness. On the contrary, it

will help to even increase flexibility

and yarn quality of the ring spinning

technique, which is already unbeat-

able in this respect. In a period of

existing overcapacities and conti-

nuously changing quality require-

ments this aspect should be of great

advantage over alternative techniques,

which present particular weak points

in this respect.

It is certainly only a matter of time,

when spinning mills without yarn con-

densation will suffer disadvantages on

the market. The purpose of this article

is to present the latest technical pro-

gress of the EliTeQCompactSet, to des-

cribe its adaptation to existing ring

spinning frames and to summarize the

technological experience acquired by

SUESSEN.

2. The EliTeQCompactSet

Ring spinning frames have a long ope-

rating life. There is practically no diffe-

rence between the individual types of

ring frames existing on the market with

regard to yarn quality achievable and

performance. Many spinning mills the-

refore raised the question – at a rather

early stage indeed – if there is a possi-

bility to modernize the existing and

proven machinery at a reasonable

expenditure so that compact yarns

can be produced.

In the SUESSEN company the ques-

tion of retrofitting played a decisive

role right from the start of develop-

ment. It was of great advantage, that

many years of experience with con-

ventional conversions could serve as

a basis.

Table shows the machine types

which can now be successfully

modernized with the EliTeQCompact-

Set. Other types of Italian or Japanese

make are being prepared. The EliTeQ

CompactSet impresses by its simplic-

ity, easy accessability and handling. It

is installed immediately after the exist-

Table : Ring Spinning Frames fit for Retrofitting

Manufacturer Machine type Gauge (mm) Tube length (mm) Doffer

RIETER G5/ 70, 75, 80, 90 220–250 no

G5/ 70, 75 180–230 no

G5/2 70, 75 180–230 yes

G30 70, 75 180–230 yes

G33 70, 75 180–230 yes

LMW G5/ 70 180–230 no

ZINSER 319 70, 75, 82,5 no restriction yes

320 70, 75, 82,5 no restriction yes

321 70, 75, 82,5 no restriction yes

JINGWEI FA 506 70 205 no

SHANGHAI EJ 507 A 70 205–230 no

EJ 519 A 75 260 no

EJM 28 70 200 no

DTM 29 70 200 no

TOYODA RY 5 70 220 no

4

SPINNOVATION No. 7

ing 3-roller drafting system and there-

fore its retrofitting to ring spinning

frames of different types is not very

complicated.

Since the spinning triangle as the

”weak point” is eliminated by the

modernization, modifications of the

original spinning geometry, which are

inevitable in some designs, are of

practically no importance.

The application for combed and

carded material, for synthetic fibres

and blends, and the production of soft

and hard compact core yarns empha-

size the unrivalled flexibility of this

system.

Modernization of ring spinning frames

with the EliTeQCompactSet comprises

the following units:

π the compacting elements EliTube

with lattice apron (Fig. ) and EliTop

(Fig. 2), HP top weighting arm and a

special front bottom roller

π EliVac negative pressure system

(Fig. 3)

π optimized (reinforced) draft gea-

rings

The cross-sectional drawing shows

the most important conversion com-

ponents (Fig. 4). It must be pointed out

that the maximum noise level created

by the negative pressure system is 83

dB (A), which is therefore below the

overall noise level of modernized ring

frames. One EliVac-Fan serves 3 Eli-

Tubes and provides the necessary

vacuum. Critical points mainly known

from the initial phase of introduction of

the EliTeQ System are now a matter of

the past owing to the purposeful tech-

nical development.

In the compacting zone, for example,

endless lattice aprons are applied

only. Interruptions as a result of break-

ing lattice aprons are eliminated.

Simultaneously, the cleanliness and

operating life of these aprons could be

substantially improved. By a new

design of the suction slot and wear-

resistant insert in the EliTube it was

possible to extend cleaning intervals

considerably. Two different suction

slots are offered (Fig. 5):

Fig.

5

SPINNOVATION No. 7

π Form A for yarns finer than Ne 30

(50 Nm) and

π Form B, marked by a delta-shaped

beginning of the slot, for yarns

coarser than Ne 30.

Finally, a new material of the wear-

resistant insert permitted to double its

operating life.

Breakdown of EliTops due to lapping

is also a matter of the past. The newly

developed EliTop is completely encap-

sulated, and the gears for speed

transfer are protected from fly and

dust. Delivery top rollers with 40 mm

diameter also help to prevent lapping,

improve the movement of the lattice

apron and protect the compacting

zone from the air-current of the travel-

ling blower. For different fibre materials

different tension draft between the two

top rollers of the EliTop is recom-

mended.

3. Quality of EliTeQYarns

3. Survey of the most important

advantages for spinners

and subsequent processes

The advantages for the yarn producer

and his customers are manifold, but

not yet fully exploited. The subsequent

survey therefore does not claim to be

complete, but it explains the extent of

quality improvement achievable with

this modified ring spinning method:

v Fig. 2: EliTop b Fig 3: Elivac negative pressure system

6

SPINNOVATION No. 7

Fig. 4

Fig. 5

Yarn producers:

π Up to 30% higher utilization of fibre

substance or 25% higher work

capacity of the yarn respectively.

π Maintaining yarn twist and spindle

speed, the ends-down rate in spin-

ning can be reduced by at least

40%.

π Yarn twist can be reduced by up to

5% for an identical or even

improved yarn quality and ends-

down rate.

π Substantial improvement of yarn

irregularity (USTER CV%) and

imperfections (USTER IPI), except

for neps.

π Reduction of hairiness disturbing

further processing steps (fibres

sticking out > 2 mm) up to a max.

of 00 %.

π The significantly better utilization of

fibre substance offers interesting

possibilities of reducing raw mate-

rial costs, by processing medium-

staple instead of long-staple cot-

ton for example.

π The possibility of spinning very soft

yarns opens extremely good pros-

pects for core yarn production and

their application as sewing

threads, for sportswear, technical

products etc.

π Fibre loss can be reduced up to

0.0% for synthetic fibres and fine

combed yarns or 0.08% for coarse

carded yarns.

π These quality improvements are

fully maintained in winding and

twisting. The loss in yarn strength

ing process is condue to the wind

siderably lower than with conven-

tional ring-spun yarn.

Downstream processes:

π Compensation of the loss in yarn

strength due to non-iron finishing

π EliTeQYarn improves all important

yarn parameters, except for neps,

and consequently increases the

yarn utility value in general.

π Owing to the dramatic reduction of

long fibres sticking out and the sig-

nificantly improved dynamometri-

cal yarn parameters, the operating

performance in the weaving mill is

considerably improved. In some

applications, only EliTeQYarns per-

mit air-jet weaving instead of the

less economical gripper technique.

π The yarn structure of EliTeQYarns is

much more abrasion-resistant.

Fibre fly is therefore reduced by up

to 50%.

π This is the reason why yarn and

needle breakages in knitting are

reduced with EliTeQYarns, although

7

SPINNOVATION No. 7

Fig. 6

Fig. 7

the yarns sometimes are not waxed

and twisted with fewer turns per

metre.

π The compactness of the yarn sur-

face and absence of long fibre

ends result in a particular brilliance

of colours when the fabrics are

printed.

π Reduced hairiness and improved

work capacity open new prospects

for substitution of two-ply yarn.

π Despite of the twist reduction in

EliTeQYarn, fabrics made of this

yarn have much less tendency

towards pilling and a better crease

recovery.

3.2 Yarn hairiness

Hairiness, i.e. the sum of all fibres

sticking out of the yarn sheath, is one

of the distinctive characteristics of a

staple-fibre yarn. While many short

hairs contribute to a good ”textile

touch” of the fabric, long hairs can dis-

turb downstream processes consider-

ably, cause high additional costs and

affect the performance of the finished

textile article.

Fibre ends exceeding 2 mm are gene-

rally found to disturb subsequent pro-

cessing steps. Certainly, in some

applications even 2 mm long hairs

may disturb, or – on the contrary –

slightly longer hairs would be prefer-

red.

Unfortunately, the measuring method

according to USTER Hairiness (H)

which is most common in practice and

measures hairiness by means of scat-

tered light, does not by far reflect the

actual conditions. Hairiness value H

corresponds to the total length of

fibres sticking out within the measured

portion of cm. Practically no diffe-

rence is made between long and short

hairs.

The ZWEIGLE measuring method – on

the other hand – measures optically

the shadow of the hairs sticking out,

which are then classified according to

their length. The two diagrams (Fig. 6

and Fig. 7) below show how wrong

evaluation of hairiness reduction can

be, if the USTER Hairiness value H is

the only factor considered.

For this purpose, all results of hairi-

ness measurements available from

our customers were collected and

average values were calculated for

individual yarn counts. Deviations due

to non-consideration of different yarn

twist, spindle speed and cotton quality

were deliberately disregarded.

Fig. 6 shows the curve of the value of

hairs > 2 mm according to ZWEIGLE

measuring method and Fig. 7 the curve

of the USTER Hairiness value H for the

8

SPINNOVATION No. 7

Fig. 8

comparable conventional and EliTeQ

Yarns. While with decreasing yarn

count the USTER Hairiness value H

suggests an almost constant reduc-

tion of hairiness, Fig. 6 makes visible

the essence of compacting: EliTeQ

Yarns reduce above all the percentage

of long hairs sticking out of combed

yarns by 90 to almost 00%. Hairiness

in the range up to 2 mm is reduced by

20 up to 40%.

Many customers therefore are not well

advised if they constantly try to

improve the USTER H value. In fact,

yarn properties cannot be further opti-

mized beyond a certain hairiness

level, but the percentage of short hairs

is excessively reduced, so that the

desired ”textile handle” may finally suf-

fer. Many studies have proved that the

advantages of EliTeQYarn concerning

hairiness are maintained up to the

two-ply yarn. The increase in hairiness

due to winding is about 30 to 40%

lower for EliTeQYarns, whereby the

advantage of hairiness obtained in

spinning is even increased after the

winding process. We know from con-

ventional ring spinning that hairiness

values differ by about 0% between

cop basis and cop tip. This percentage

is reduced to 3% and less by the Eli-

TeQCompact Spinning Method. As a

result, the well-known cyclic variation

of hairiness within the same package

is reduced considerably.

But we should also refer to risks which

must not be ignored. The smoother Eli-

TeQCompact Yarns, i.e. if hairiness

reduction was carried to extremes

(see above), can cause the yarn to

slough off during winding. This is often

the real reason, if clients complain of

too many cops ejected at the auto-

matic winder.

In some articles the extremely low

hairiness level of EliTeQCompact Yarns

can have the result that deviations

of 0.8 of USTER hairiness H are

already shown as a defect. In this

respect, the necessity of carefully

observing the service life of ring

travellers must be pointed out (please

also see chapter 4).

Improvements in winding technique,

which can now be adapted, including

optimization of the relevant clearers,

enable the necessary control of hairi-

ness online at the automatic winders.

3.3 Yarn strength

The condensing of fibres after the

drafting process, but immediately

before imparting yarn twist, changes

the orientation of fibres in the yarn

cross-section. The decrease of fibre

density between yarn core and outer

layers known from conventional ring

yarn is substantially reduced. Simi-

larly, the migration of some fibres from

the yarn core to outer layers and vice

versa is much less pronounced in

EliTeQYarn due to the elimination of the

spinning triangle. When the yarn is

subjected to tensile strength, the

fibres in the yarn cross-section are

loaded more uniformly, and in the last

analysis this is the reason of the

higher work capacity of such yarns.

Fig. 8 shows the average improvement

of work capacity of EliTeQYarn in com-

parison with conventional ring yarn on

the basis of industrial data made

available to us.

The relations approximately prevailing

in the yarn cross-section concerning

the percentage of enclosed air and

fibre density are shown in Figs. 9 and

0 in imitation of earlier studies.

For the sake of completeness it is to

be mentioned that as a result of this

9

SPINNOVATION No. 7

Fig. 9

Fig. 0

Fig.

modified structure EliTeQYarns are

somewhat more ”lively” and show a

slightly higher tendency towards

snarling, which however is usually

compensated by the optional twist

reduction. This influence on yarn

structure is also reflected by twist

measurement, where the pre-tension

weights must be lighter.

EliTeQYarns achieve their maximum

yarn strength with a twist multiplier,

which is about 20 am (0.65 ae) lower

than for a comparable conventional

ring yarn. This is synonymous with a

real potential for production increase

in twisting.

3.4 Yarn irregularity

and imperfections

The results obtained by our clients are

summarized in Fig. . Yarn irregularity

(USTER CV%) and imperfections

(USTER IPI), apart from neps, are sub-

stantially improved with the EliTeQ

Compact Spinning System. This is

astonishing, as the fibre strand is

compacted after the drafting system,

so that the drafting process itself is

unaffected. The usually considerable

improvements cannot be attributed

alone to the process-related tension

draft in the condensing zone.

Consequently, such defects must

originate in the spinning triangle,

obviously in combination with the

traverse movement at the front roller

pair, often exaggerated in practice.

0

SPINNOVATION No. 7

Fig. 2

Temperature in ΩC

As a result of the strong decrease in

long hairs, however, yarn defects are

no more conceiled and they are more

visible in the fabric. A more sensitive

setting of optical and capacitive clear-

ers is therefore required. Capacitive

clearers offer the advantage of defini-

tely more signal for an extra precise

detection of yarn defects close to the

yarn body. This explains why compact

spinning mills prefer capacitive sen-

sors.

4. Important Basic Rules

for Spinning with

the EliTeQCompactSet

One or the other experience made in

industrial practice and enumerated

below may seem trivial in reading. But

it is just the sum of many so-called ”tri-

fles” which decides on success or fai-

lure of a new method. Some of our

clients know this from bitter experi-

ence in spite of good advice from our

side. It is therefore important to realize

already before introduction, that the

compactation of yarns is a spinning

method to produce condensed yarns

by means of compressed air, which

are definitely less hairy.

Although ring spinning frames retrofit-

ted with the EliTeQCompactSet pro-

duce much less fly owing to the sub-

stantially reduced fibre loss, they

attract fly and dust from adjacent

machines due to the negative pres-

sure of suction air. It is therefore

recommended to install modernized

and standard ring spinning machines

in separate rooms or sections. Condi-

tions are therefore similar to rotor

spinning machines, which for the

same reasons should not be installed

together with ring spinning frames.

The requirements for cleaning and

maintenance are higher. The length of

cleaning intervals can be influenced,

however, and depends on the extent to

which the ambient air of these machi-

nes is polluted with fibre and dust par-

ticles.

Depending on the prerequisites, like

dust content of air, siliceous particles,

fibre material, yarn count and finally

cleanliness of the machine, the ope-

rating life of lattice aprons is between

7 and 4 months.

Together with the general cleanliness

in the spinning room and the fibre and

dust content of air, air-conditioning

plays a more important role than in

conventional ring spinning. Air

exchange of at least 33 per hour is

recommended. The absolute water

content of air should not exceed

g/kg, what corresponds approxima-

tely to the following ranges for humid-

ity and temperature according to the

well-known i-x diagram. Fig. 2 shows

the approx. relation of Relative Humid-

ity and Temperature to get an absolute

water content of g/kg.

Sticky substances like honey-dew

shorten the necessary cleaning and

washing interval of lattice aprons and

increase the risk of insufficient com-

pactation, resulting in defective cops.

The ends down rate with the EliTeQ

CompactSet is very low. Some spin-

ning mill managers may be seduced to

overhaste the assignment of larger

operating areas. It is often overlooked

that survey and control activities of

operators generally increase with

compact spinning. Our customers the-

refore receive a catalog of important

instructions with the EliTeQCompact-

SPINNOVATION No. 7

Sets to avoid serious problems right

from the start.

In the introduction phase of this new

spinning method, the reduced hairi-

ness of EliTeQYarns caused a lot of

excitement at our customers concern-

ing the choice of spinning rings and

travellers and their operating life.

Meanwhile, however, the manufactur-

ers of these important spinning acces-

sories have acquired experience and

made good progress, so that they are

competent advisors for compact yarn

spinners.

Nevertheless, there are some basic

rules which should be observed from

the beginning:

π Spinning rings with a profile in

antiwedge or asymmetrical design

are recommended. As in conven-

tional ring spinning, the ring quality

depends on the traveller speed

and on the calculated operating

life of the rings. Information has

been received that in some cases

the ORBIT system is applicable.

π The decisive criterion is the rapid

formation of a lubricating film bet-

ween ring and traveller. This is

complicated by the reduced hairi-

ness. It is therefore advantageous

to choose a relatively close pas-

sage, which is possible for exam-

ple with traveller types like C UL

udr and C EL udr of Braecker or El

hft of Reiners & Fuerst.

If CoreYarns are spun with the

EliTeQCompactSet, almost no res-

trictions are valid for the travellers,

because these yarns are usually

spun with substantially lower trav-

eller speeds due to different prere-

quisites.

Irrespective of whether CoreYarns

or staple fibre yarns are spun,

rings must be run in very carefully.

Customers are advised against the

shortened running-in programs

propagated by some ring manufac-

turers. It has proved successful to

reduce the spindle speed by about

30% in the initial phase of 30 minu-

tes after a traveller change. Our

clients change travellers at inter-

vals between 7 and 5 days

depending on the ambient condi-

tions.

Utmost importance has to be atta-

ched to the centering of spinning

rings, balloon-control rings and

yarn guides.

π No precise information can be

given on maximum possible travel-

ler speeds. It should be observed,

however, that depending on raw

material and hairiness level a

reduction of the maximum traveller

speed by up to 0% is sensible in

some cases.

π It is recommended to set traveller

clearers by 0. to 0.2 mm closer

than advised in the manuals of ring

manufacturers.

π The centring of spinning rings, bal-

loon control rings and thread gui-

des is of utmost importance for the

overall performance of the com-

pact ring spinning machine and

compact yarn quality.

Due to the process-related traverse

movement of 4.5 mm only of the roving

at the front roller pair of the drafting

system, buffing intervals of top roller

cots are necessarily shorter. Depend-

ing on main draft, fibre material and

yarn counts, top roller cots should be

buffed every 8 to 2 weeks.

It is recommended to reduce the cot

diameter by approx. 0.3 mm per buff-

ing. The minimum top roller diameter is

26.5 mm, of which result 8 buffing

cycles. Surface roughness after buff-

ing should be about Ra = 0.9.

It has proved successful to provide all

EliTops of one buffing cycle with the

same colour mark.

5. Summary

In the three years since its introduc-

tion to the spinning industry, the spin-

ning of compact yarns has made tre-

mendous progress. This is also

reflected by the admission of these

yarns to the current USTER Statistics

200. It is almost impossible to ima-

gine a future of ring spinning without

this interesting variant. For many spin-

ning mills the possibility of transform-

ing their existing ring spinning instal-

lations to produce compact yarn,

exclusively offered by SUESSEN with

the EliTeQCompactSet, is the most

interesting alternative with regard to

costs. It enables them to utilize the

important advantages of this spinning

method quickly and at moderate

costs. This will finally give a strong

impetus to the whole market of com-

pact yarns. Dr. N. Brunk

2

SPINNOVATION No. 7

Solutions for Open-End Rotor Spinning . . .

Fig.

Fig. 2

Rotor E% cN/tex Uster Imper- Staff ends downrpm CV% fections

POLYESTER (PES)and MIMA Navels . . .

We report regularly about new items

which are available within the range of

spinning accessories, but from time to

time we also comment on certain top-

ics for a second time, if new practical

experience has emerged from the

mills after a longer period.

In the case of MIMA navels it is

actually a fact that in the course of

time these have become a kind of

standard for the spinning of POLYES-

TER and also for the processing of

PES blends. There is hardly a spinner

who has experienced the advantages

in his own mill and who would be pre-

pared to do without this small, but

highly effective spinning accessory.

Each producer of polyester knows that

the production with this material is

very rarely limited by the capacity of

the spinning frame, but mainly due to

the fact that fibre damage at the navel

does not permit higher rotor speeds.

These thermal fibre damages lead,

for example, to a different affinity for

dyestuffs. In general, the navel, when

spinning PES, is partly responsible for

the higher tendency towards lateral

fibre displacement and for the

increasing abrasion (staff) at higher

rotor speeds, and thus determines

yarn quality.

Design and material permit MIMA

navels, in comparison with nozzles

used up to now, to increase rotor

speed by 5-20% when processing

PES or PES blends. In spite of the

higher rotor speed possible, the yarn

quality achieved is excellent, i.e. in

most cases when compared with con-

ventional navels also at higher speeds

even better. Fig. shows a direct mill

comparison when spinning a 00%

PES quality using CK4 navels (steel)

and MIMA navels.

It can be seen that MIMA navels pro-

vide excellent results all-round, whe-

reby the differences are not only

apparent in the general yarn test para-

meters, but also significantly in res-

pect of fibre abrasion (staff) and ope-

rating performance. For higher rotor

3

SPINNOVATION No. 7

Fig. 3

Fig. 4

speeds, when processing PES or PES

blends, MIMA is thus the first choice.

A further example comes straight from

a customer who processes a blend of

70/30% PES/cotton (Fig. 2). A KN4

navel has generally been used in this

case. Subsequently, a change to MIMA

2 has been made (this type of navel is

frequently used for operating with

rotor speeds in excess of 00,000

rpm, whereas MIMA navels are mainly

employed for rotor speeds up to

approx. 00,000 rpm.)

Also in this case the result was

unequivocal: Only with MIMA navels

are speeds of this magnitude in

respect of yarn test parameters or

operating performance possible

without any difficulties.

Finally, an impressive example, which

we have received from one of our cus-

tomers, and which clearly demonstra-

tes, why the client has decided to

change to MIMA navels (Fig. 3). The

”restraint” towards higher rotor speeds

in this case was also the conventional

navel, which is clearly demonstrated

by the high ends-down rate. A suitable

example for a problem and its solu-

tion.

The development in the field of navels

is never completed. New materials,

new ideas and new demands from the

spinning mills force development to

continue. We shall carry on to put this

into action in order to provide maxi-

mum possible advantages for our cus-

tomers.

Cotton Yarnsand GSQ Rotors . . .

A further topic is the SUESSEN GSQ

rotor. The rotor design GSQ230BD is

being successfully used today, parti-

cularly for the spinning of 00% cotton

in the finer range of yarn counts. In

view of the typical G groove, these

yarns are predominantly used in the

knitting industry.

The GSQ rotor is a further develop-

ment of the well-known and success-

ful G rotors, mainly distinguished by

superior yarn test parameters as well

as excellent spinning stability.

4

SPINNOVATION No. 7

Knitting yarns, as a rule, are spun with

a relatively low twist multiplier, and for

this reason they are more sensitive in

respect of spinning stability and do

not have the same strength as corres-

ponding yarns for weaving. A very high

medium yarn strength is not absolu-

tely necessary in knitting, nevertheless

the weak sections in the yarn, res-

ponsible for end-breaks, are also

reduced.

The diagrams (Fig. 4 and 5) show the

average values achieved for yarn

counts ranging from Ne 4 to Ne 35

with various cotton qualities. These

rotors allow to manufacture yarns of

highest quality at high production

rates.

In the U.S. market GSQ rotors are also

very popular for PES/cotton blends.

The resulting yarns are also very com-

mon in the knitting industry.

In a nutshell: Spinning accessories

should not be seen as wearable work-

ing parts, but as efficient tools, which

may perhaps enable the spinner to

obtain decisive advantages. UR

Fig. 6

Fig. 5

Fig. 7

5

SPINNOVATION No. 7

Harriet & Henderson Yarns, Inc. , NC, USAInterview with Jim Booterbaugh and Rick Bartonby Thomas Wiget and Jim Blalock, American Suessen Corp.

In mid 2000, Harriet & Henderson

Yarns, Inc., Henderson, NC, USA plac-

ed an order with American Suessen

Corporation for frames with 04

spindles each of Fiomax E and 3

additional frames of 04 spindles

each of Fiomax prepared for EliTeQ.

These frames were delivered and

installed in their Clarkton Plant in

Clarkton, NC, USA. Previously, Harriet

& Henderson has purchased SC -M

SpinBox modernizations for two other

plants. Following is an interview with

Jim Booterbaugh, Vice President of

Manufacturing, and Rick Barton,

Director of Operations for the Clarkton

and Bladen Plants:

SPINNOVATION: Gentlemen, could

you please give us some background

information about Harriet & Henderson

Yarns?

Mr. Booterbaugh: Yes. Harriet & Hen-

derson was formed in 895 in Hender-

son, NC. H&H currently has 7 yarn

manufacturing plants, with a capacity

of approximately 80 million pounds of

yarn annually. H&H produces cotton

and polyester/cotton blends of ring

and open-end yarn.

SPINNOVATION: Why did H&H decide

to purchase the EliTeQCompact Spin-

ning System?

Mr. Booterbaugh: H&H wanted to have

a product that was differentiated from

the rest of the ring spun carded yarns

in the market. Trials run on the EliTeQ

CompactSet proved that not only was

evenness and strength better, but also

the shedding of the yarn. In discus-

sions with knitters, shedding is an

issue during the knitting and dyeing

processes when carded ring spun

yarn is used.

Mr. Barton: H&H also saw the oppor-

tunity to differentiate our products

without the normal risk of failure.

Based on the EliTeQCompactSet’s

ability to spin compact and conven-

tional yarns, the risk was minimal.

Also, failure did not mean scrapping of

the equipment, as had been the case

with other type of technologies. The

high reward side of the equation was

EliTeQ’s ability to make a high quality

of yarn that could not be duplicated by

our competitors. This high reward/low

risk ratio made EliTeQCompactSet an

easy decision.

SPINNOVATION: How has H&H bene-

fited from the EliTeQCompactSet?

Mr. Booterbaugh: First and foremost,

H&H has a product that is consistently

sold out, during a time when the

remainder of the domestic textile

business is slow. Second, H&H has a

product that has superior appearance

and hand to any other carded ring

spun yarn produced.

Mr. Barton: The EliTeQCompactSet

allows H&H to engineer yarns for spe-

cific end uses and penetrate markets

previously not possible.

SPINNOVATION: Has the use of the

EliTeQCompactSet affected fiber cost?

Mr. Booterbaugh: Only slightly. At this

point, H&H has not tried to take

advantage of lowering raw material

grade. H&H is interested in producing

a premium quality product with a nor-

mal fiber grade.

SPINNOVATION: What is your count

range?

Mr. Booterbaugh: To date the yarns

produced have ranged between 2/

and 30/, but the majority of the

products are between 8/ and 30/.

6

SPINNOVATION No. 7

SPINNOVATION: How does EliTeQYarn

perform on the ring frame, i.e. ends

down, lint, cleanliness etc.?

Mr. Barton: Wonderful! Just this morn-

ing, the Production Manager walked

across the entire floor and only

counted a total of 5 ends down on all

the EliTeQFrames. The operators often

comment how clean the air is. They are

used to working in an open-end envi-

ronment and the EliTeQoperation is

just as clean. The linked winders

perform at an exceptionally high

efficiency and they too stay clean.

The EliTeQCompactSet itself is very

good and reliable. With stable air

conditioning, there are no damaged

components. Typical, run-of-the-mill

manufacturing variations that cause

quality problems in ring spinning do

not exist with EliTeQCompactSet.

Mr. Booterbaugh: The ends down level

on the EliTeQFrames are about the

same as the EliTeQ-prepared frames,

but the EliTeQFrames are running at

least 5 percent faster. I agree with

Rick, the lint in the spinning room is

noticeably lower than in the other H&H

ring spinning plants, but the air turns

often in the plant.

SPINNOVATION: What type of pro-

ducts does your yarn go into?

Mr. Booterbaugh: Mostly knit apparel.

There has been some terry yarn pro-

duced.

SPINNOVATION: What are your EliTeQ

Yarns competing against in the

market?

Mr. Barton: Of course H&H is compet-

ing against carded yarns spun domes-

tically and abroad. The EliTeQYarn is

also able to compete against combed

cotton yarns due to its evenness and

soft hand in the fabric (due to a low

twist level). With conventional yarns, it

would be difficult to spin with such a

low Twist Multiplier.

Mr. Booterbaugh: H&H yarns compete

against carded and combed yarns,

either as a premium carded alternative

or a combed yarn substitute.

SPINNOVATION: How do H&H’s cus-

tomers rate EliTeQYarn?

Mr. Barton: They love it. A large num-

ber of the EliTeQYarn’s performance

incentives are clearly marketable. The

low hairiness values result in better

running conditions for our customers.

Their plants and machines stay clea-

ner and they recognize this. The soft

hand I mentioned earlier also impres-

ses the customers. This soft hand is

hard to duplicate with conventional

yarns.

Mr. Booterbaugh: H&H has already

earned a quality award from one

customer. Our other customers are

satisfied with the performance of

the yarn.

SPINNOVATION: What are your

thoughts on the future of EliTeQYarns?

Mr. Barton: EliTeQYarn in the future will

provide opportunities to spin finer

counts with reduced raw material

costs and reduced manufacturing

process (eliminate combing or twist-

ing) which will more than offset the

additional cost of EliTeQCompactSet

over conventional spinning.

SPINNOVATION: How helpful have the

SUESSEN technical people been?

Mr. Booterbaugh: As in any new instal-

lation, it took our associates awhile to

get used to the SUESSEN techni-

cians, but the SUESSEN technical

people formed a strong bond with our

technicians which contributed to the

success of the current operation.

SPINNOVATION: Mr. Booterbaugh,

your company has also purchased

several SUESSEN Compact SpinBox

SC -M conversions. Why did H&H

purchase the SC -M SpinBox instead

of new machines?

Mr. Booterbaugh: H&H had SE-8

machines in rooms that could not

handle longer machines. For a new

plant, or if you are fortunate to have

all the floor space you want, new

machines are often preferable. In

those cases you can maximize rotors/

machine and get double productivity

increases. In the case of our two

plants that use the SC -M, the maxi-

7

SPINNOVATION No. 7

mum number of rotors that could be

used was 92. It made sense from a

value standpoint to convert existing

machines and spend considerably

less money.

SPINNOVATION: Which features of

the SpinBox SC -M impressed you

the most?

Mr. Booterbaugh: The grease car-

tridge, the relocating of the feed shaft

which allows a one-piece fiber chan-

nel, and the improved airflow through

the combing roll housing.

Mr. Barton: The EC bearings have led

to longer cleaning intervals and less

downtime for cleaning.

SPINNOVATION: How has the Spin-

Box SC -M benefited H&H?

Mr. Booterbaugh: There has been a

20% increase in production with a

50% reduction in ends down, and a

slight improvement in yarn quality.

SPINNOVATION: What has been your

overall experience with SpinBox SC

-M?

Mr. Booterbaugh: The conversions

brought dead machines back to life.

We have been especially pleased with

how well the conversions work on yarn

counts of 24/ and finer. Also, from

experience I will say that the best

return will come from the conversions

when the piecer and take-up zones

are rebuilt when the conversion is

done – just as SUESSEN recom-

mended.

SPINNOVATION: It has been good dis-

cussing these issues with you. Thank

you both for your time.

Jim Booterbaugh (VP Manufacturing)

From left to right: Rick Barton (Director of Operations for Clarktonand Bladen Plants), Michael Lee (Production Manager), ThomasWiget(American Suessen Corp.)

8

SPINNOVATION No. 7

Cotton Inc. , USA, in favorof the SUESSEN EliTeQCompactSet

Cotton Incorporated, USA, is the

world-wide acknowledged Research

and Promotion Organization for the

U.S. Cotton Industry, with offices all

over the world as in Japan, Switzer-

land, China etc.

The Cotton Incorporated Mission Sta-

tement is ”. . . to increase the demand

for and the profitability of cotton

through research and promotion.”

Only recently, Cotton Inc. published

the following article in the American

textile magazine TI issue November

200 (Textiles Industries, the former

ATI and now the Textile World) as well

as on their own homepage concerning

the SUESSEN EliTeQCompact Spin-

ning System:

An EliTe Alternative for Higher

Quality, Lower Cost Ring Spun Yarns

by Cotton Incorporated World Head-

quarters

In the ultra-competitive business of

textiles and apparel, adding value to

products can provide a potential edge

in the marketplace. The bigger chal-

lenge is how to do this cost effectively,

as prices at retail for finished goods

have actually decreased over the last

several years.

While many consumers might not rea-

lize it, the use of ring spun yarns can

certainly add value, as they impart

attributes to garments that are difficult

not to notice: softer hand, smoother

appearance and better wear, among

other things. This is especially true for

cotton and cotton rich fabrics. The

problem is the cost of these high qua-

lity yarns.

So when David Clapp, Director, Techni-

cal Services, Fiber Processing at Cot-

ton Incorporated, learned of a new

technique for manufacturing ring spun

yarns that was said to be more cost

effective – known generically as com-

pact ring spinning – his interest was

piqued. It is, after all, his job to find and

guide the development of yarn tech-

nologies that could ultimately enhance

cotton products. Given Cotton Incor-

porated’s overall mission to increase

the consumption and profitability of

cotton, Clapp wanted to see if com-

pact ring spinning was indeed more

efficient and could yield a higher qua-

lity yarn than conventional ring spin-

ning. More importantly, he wanted to

be able to prove its benefits so that

this information could be shared with

our very best customers.

”A number of machinery manufactur-

ers had a version of compact ring

spinning equipment, and we looked

carefully at all of them,” Clapp reports.

”Through common sense, our experi-

ence and some other factors, we con-

cluded that the Suessen EliTeQ com-

pact ring spinning system offered the

best operational design for our

research purposes.”

Acquiring this limited production,

state-of-the-art machine, however,

could have proven a bit difficult, as

many others in the industry also saw

its potential. ”We were able to get a

machine due to in large part to Suess-

en’s knowledge of what we did

recently to evaluate and demonstrate

Murata’s Vortex equipment,” Clapp

maintains. ”Our research and develop-

ment with that equipment proved valu-

able to spinners and vertical mills as

they considered its effectiveness in

processing cotton fiber.”

Compact spinning can best be de-

scribed as a modification of the basic

ring spinning frame that preserves

fiber alignment and parallelization up

to the point of twist insertion. While

9

SPINNOVATION No. 7

manufacturers approach the concept

in different ways, the design of the

EliTeQ assembly consists of an auxili-

ary front top roller and a slotted,

hollow tube fitted with a lattice apron.

After the fibers initially collect and

form a strand through Suessen’s pro-

ven drafting system, the strand soon

reaches the EliTeQ assembly, where

the slotted tube creates an air current

through the lattice apron. The air curr-

ent seizes the fibers as they leave the

front roller nipping line, condensing

the fiber strand. The result is the dra-

matic reduction of the spinning

”triangle” and better fiber alignment.

Once obtained, the task of testing this

new system was put in the capable

hands of Jim Lisk, Fiber Processing

Engineer, an industry veteran with an

extensive background in manufactur-

ing and selling yarns. His initial runs

comparing these compact yarns to

conventional ring spinning showed

differences that were ”quite dramatic.”

”Because of better fiber alignment

preserved until the point of twist inser-

tion, more fibers are used in the yarn

structure, resulting in a stronger yarn,”

Lisk explains. ”In our initial twist study,

we also found EliTe reaches maximum

strength at a much lower Twist Multi-

plier (TM) than conventional ring spin-

ning, in the 3.5 to 3.6 TM range, versus

4.3, respectively. This opens the door

to higher spinning speeds, due to the

reduced twist, which can increase pro-

ductivity 5 to 20%. And,” he adds,

”since less fiber is sticking out of the

yarn bundle, there is less hairiness,

which is preferable for a number of

applications.”

These positive results were further

confirmed in trials comparing com-

pact ring spun yarns with conventional

ring spun yarns produced at National

Textiles.”We used the same carded

cotton roving they use to spin a mid-

range 7.5/s yarn,” Lisk reports.

”Matching their conventional 3.9 TM,

we increased breaking strength from

5.9 to 8 grams/tex, and reduced hai-

riness from 6.83 to 5.29. By reducing

TM to 3.2, their conventional spun

breaking strength of 5.9 was equaled

and hairiness was still at 5.9,” he adds.

Compact technology also presents

another possibility: Not only can you

make higher quality yarns faster from

the same raw materials using a lower

twist, you could also use a wider range

of raw material to make a comparable

yarn at a more competitive price. Lisk

ran trials spinning 30/s using raw

cotton in various states, including

recycling of comber noil up to 20%.

”We wanted to see just how much noil

we could put back in and still produce

a viable yarn,” he explained. ”We saw

the same kind of increases in strength

and decreases in hairiness as we did

in previous trials. EliTe yarn spun from

00% carded cotton with a 3. TM is

actually stronger and less hairy than

conventional ring yarns spun from

00% combed cotton with a 3.2 TM,”

Lisk reported. ”When EliTe yarn was

spun from carded 90%/0% cotton/

noils with a 3. TM, it is stronger than

conventional ring yarns spun from

00% carded cotton with a 3.4 TM, and

as strong as 00% combed conven-

tional ring with a 3.2 TM. Therefore,” he

asserts, ”Compact spinning may allow

the spinner to run a wider range of

fiber qualities and/or reduce twist to

produce the required strength.” He

also noted, however, an increase in

imperfections as fiber quality is reduc-

ed from 00% combed to 80/20 cot-

ton/noils, and the use of compact

spinning technology did not generally

lower the number of imperfections.

But overall positive implications of this

new technology could be tremendous.

”It’s going to be fantastic when used

as the warp yarn in weaving,” Lisk

says. ”The increase in strength and

reduction in hairiness could allow

weavers to change fabric construc-

tion, increasing warp cover and reduc-

ing filling cover, thereby increasing

loom productivity.” Using the techno-

logy for knits should also be effective

he noted. ”Knit fabrics made from

lower twist compact yarns demon-

strate lower torque and fabric skew for

better handling.

The compact ring spinning trials, as

well as trials on all the other short sta-

ple systems continue at Cotton Incor-

porated’s state of the art research

facility and we urge you to stop by to

see what we are looking to help insure

cotton’s future. (Cotton Inc.)

SE7·SE8·SE9·SE0

SC-M·SC2-M

sSpindelfabrik Suessen · Schurr, Stahlecker&Grill GmbH · Postfach 320 · D-73075 Süssen · Federal Republic of Germany

Tel. ++49762 5-0 · Fax ++49762 5-488 · e-mail: premium.parts@suessen.com · http://www.suessen.com

Prem

iumParts

There are only two types of spare parts:originals and others . . .

SUESSEN develops and manufactures the original spare parts forSE 7, SE 8, SE 9 and SE 0 SpinBoxes.

Only with SUESSEN PREMIUM PARTS you can be sure to receivethe proven quality of original spare parts. Only with SUESSEN PREMIUM PARTSyou will participate in innovations of the company leading in the development

of rotor spinning for 30 years.

. . . trust the proven quality fromthe Original Spare Parts Manufacturer.We would be glad to demonstrate our latest developments and provide you

directly with our original spare parts.

2

SPINNOVATION No. 7

Fig.

Portrait of ”Textilgruppe Hof” (Germany)and their Experience with the Modernizationof Rotor Spinning Machines by SUESSEN

History of the Company

The history of the company reveals a

long tradition in the manufacture of

textile fabrics in the district of Hof,

located in the north-east of the Ger-

man region of Oberfranken.

Already in 853, the magazine ”Hofer

Wochenblatt” reported about inten-

tions to establish a mechanical cotton

spinning mill in Hof, which was

actually launched, however, in the year

869 when ”Neue Baumwollspinnerei

Hof” was founded.

When this mill joined ”Mechanische

Weberei” a short time later to form

”Neue Baumwollspinnerei und Webe-

rei Hof”, this was the moment of laying

the foundation-stone for the group of

textile companies to which it should

develop.

By the acquisition of several compan-

ies, like ”Spinnerei Nördlingen KG”

and ”Feinspinnerei Hof AG” in 967,

and by the participation in the enter-

prise ”Vogtländische Baumwollspinne-

rei” two years later, the group pursued

consequently its goal of expansion.

With effect from st July 996, ”Textil-

gruppe Hof” underwent a radical reor-

ganization and became a holding

company. ”Neue Baumwollspinnerei

und Weberei Hof AG (NSH)” acted as a

holding company with its individual

companies.

In early 997, ”Südwolle AG” (Nürn-

berg), one of the largest worsted spin-

ning mills world-wide, acquired 80% of

the shares of ”Neue Baumwollspinne-

rei und Weberei Hof AG”, which today

has listed stocks as ”Textilgruppe Hof

AG”. Apart from installations abroad,

the manufacture now concentrates on

Hof and its environs.

Range of Products

In ”Hof Garn GmbH” under the

umbrella of the holding company

”Textilgruppe Hof AG” the spinning

activities of ”Textilgruppe Hof” are

combined.

Currently, about 840 employees pro-

duce and market approx. 32,000 tons/

year of yarns, 2-for- plied yarns and

chenille yarns as well as superior

elastic two-ply yarns on high-end

machinery.

The product range comprises carded

and combed cotton yarns, most differ-

ent blends (tuft blending and draw-

frame blending) up to pure synthetics,

which are spun by the conventional

ring spinning method, but also by the

highly efficient OE rotor spinning proc-

ess.

Ring and rotor yarns are produced in

four mills, each of them being specia-

list for a certain product group.

”Spinnerei Moschendorf” near Hof,

with a capacity of about 3,000 spin-

dles and 5,600 rotors, mainly spins

rotor yarns (Ne 6 to Ne 40) and ring

yarns (Ne 6 to Ne 6) from pure cotton

for weaving and knitting.

22

SPINNOVATION No. 7

The second enterprise in Hof, ”Spin-

nerei Schützenstrasse”, produces in

its ring spinning mill with almost

29,000 spindles a yarn count range

from Ne 2 to Ne 36 from carded and

combed cotton, PES/Co and

Co/Modal blends, as well as pure syn-

thetics and blends. The rotor spinning

mill with 2,600 rotors is specialized on

00% synthetic yarns and yarns from

synthetic blends and cotton blends.

In ”Spinnerei Nördlingen” the majority

of the product range is covered by

ring yarns of combed or carded cotton

and cotton blends from Ne 8 to Ne

40. The OE machines (2,60 rotors)

produce cotton yarns up to Ne 38 and

blends for the knitting and weaving

sector.

”Spinnerei Hoflana” mainly produces

the above-mentioned 2-for- plied

yarns and chenille yarns.

Inclination to Invest

The holding company ”Textilgruppe

Hof AG” is always working on an opti-

mization of its market position in all

sectors. Naturally, one of the prerequi-

sites is the corresponding inclination

to invest. At the end of last year, the

group completed a fundamental

investment programme, which com-

prised a volume of about 75-80 million

EUR and was distributed on all fields

of activity within a period of four years

only.

Fig. 2

Fig. 3

Fig. 4

23

SPINNOVATION No. 7

Fig. 5

Fig. 6

Fig. 7

Within the framework of this invest-

ment programme,”Textilgruppe Hof

AG” decided for the modernization of

its Autocoro rotor spinning machines

with the new SUESSEN SpinBox

generation.

Experience with Modernization

of OE Machines by SUESSEN

In the last three years, the mills of

”Nördlingen”, ”Schützenstrasse” and

”Moschendorf” gradually modernized

all 3 Autocoro rotor spinning machi-

nes of the types SE 8 and SE 9 with

the SC -M/2-M SpinBox as well as

with the SQ Modernization Package.

These three spinning mills of ”Textil-

gruppe Hof AG” are now in a position

to look back on practical experience

with the SC SpinBox on a wide basis,

acquired during the last months or

years.

Whatever material they spun, it

became evident that the OE machines

modernized by SUESSEN were consi-

derably profitable with regard to

π yarn quality

π ends-down rates

π delivery

so that the investment was paid back

within a short time.

The following tables show a survey of

the various demands of these three

rotor spinning mills of ”Textilgruppe

Hof AG”, who modernized their machi-

nes with SUESSEN. (FR)

24

SPINNOVATION No. 7

Carbon Fiber Traverse Rodfor SUESSEN SC and SQ Modernizationof Autocoro Rotor Spinning Machines

As a part of the SC/SQ Modernization

Packages offered by SUESSEN, often

the so-called CFR conversion is

included. This simply means replacing

the original steel traverse rod with a

carbon fiber rod, and of course inclu-

des the proper bearings. It is offered to

increase the take-up speed, particu-

larly with coarser counts.

This article will try to explain the physi-

cal background of this conversion.

. Introduction

On all major OE machines the yarn is

guided onto the cross-wound pack-

age (either cylindrical or tube) by

means of yarn guides mounted to the

traverse rod.

This traverse rod runs the length of the

machine, on both sides, and is driven

by the traverse gear mechanism

mounted on the head end of the

machine. (On some new machines, the

rod is driven from both ends. This

makes no difference, as far as the fol-

lowing is concerned.)

As the winding angle of the cross-

wound package must be held con-

stant (generally between 30Ω to 42Ω),

the speed of the traverse rod increa-

ses as the take-up speed goes up.

This increase in speed has three

major effects, which will be described

below:

2. Load on the

Traverse Gear Mechanism

The traverse rod moves from left to

right and back, it makes strokes, which

determine the ”height” of the wind on

the package.

Consequently, the rod must be accele-

rated and decelerated continuously. At

the points of reversal, its speed is

zero.

Let us start at the left point of reversal:

The speed of the rod is zero. The trav-

erse mechanism vigorously starts

pushing the rod to the right, accelerat-

ing it. As it approaches the right point

of reversal, the traverse mechanism

starts slowing down the rod, decele-

rating it. As it reaches the right point of

reversal, it has zero speed. Immedia-

tely, the traverse mechanism starts

pulling the rod to the left, accelerating

it . . . . . .the game continues.

Physically speaking, deceleration is

simply ”negative” acceleration, so for

the remainder of this article, we do not

have to distinguish any more.

The law governing this kind of motion

is the venerable Newton’s Law:

Force =mass x acceleration,

or, in symbols: F=m * a ()

F = Force acting on the traverse gear

mechanism. The higher this force,

the higher the load on it

a = (maximum ) acceleration of the

rod, this usually occurs at the

points of reversal

m = mass (”weight”) of the traverse

rod

For technological reasons, the rod

should be at its points of reversal for

as short a time as possible, else the

undesirable spider webbing occurs on

the packages. Hence, the mechanism

must vigorously push the rod, giving it

a high acceleration.

As is evident from formula1, the smal-

ler the mass of the traverse rod (the

lighter it is), the smaller the load on the

traverse gear mechanism.

As the CFR only weighs about 50% of

the corresponding steel rod, the load

on the traverse mechanism is reduced

correspondingly. The load on the trav-

erse mechanism is directly related to

its life time.

The density of the rod is only 20% of

that of steel, but one must include the

masses of the yarn guides, couplings,

etc.

25

SPINNOVATION No. 6

Where does the take-up speed of the

machine come into play?

Let us simplify just slightly, and

assume, that the speed profile of the

traverse rod is a sinus curve. (Fig. )

V(t) = V0 * sin (v * t).

V0 = maximum speed of the rod (2)

v = determines the time it takes to

make one stroke: T = ö / v (3)

As the winding angle should be held

constant, it is apparent, that the faster

the take-up speed, the smaller T,

hence the larger v must be.

The path curve is:

S(t) = ∫ v(t) dt = - (V0/v) * cos (v * t) (4)

Here V0 / v = /2 of stroke, this must

be constant, hence, if v goes up, so

must V0 !! (5)

The acceleration curve is

a(t) = d V(t) / dt = V0 * v * cos (v * t).

The maximum acceleration

is aMAX = V0 * v (6)

To summarize:

If the delivery speed should be

increased, v must increase, and

therefore V0 must also increase!

Therefore, the acceleration must

increase, and therefore, the load on

the mechanism increases!

Example:

If the delivery speed increases 40%,

the load on the traverse mechanism (if

the traverse rod remains the same)

increases by 96%, in other words, it

becomes twice as large!

On the other hand, if the weight of the

traverse rod is cut in half, the load

remains the same.

As the CFR only weighs 50% of the

steel rod, it is apparent that even after

a substantial increase in delivery

speed, the load on the traverse

mechanism is actually reduced.

3. Machine Vibrations

As the delivery speed is increased, mill

people observe that their machine

starts vibrating more.

Again, our old friend Mr. Isaac Newton

gives us the answer. This time, his law

is called the

conservation of the total impulse, or

in symbols: d/dt (m*V) = 0 (7)

This law is conceptually much more

difficult than () above. Essentially,

what it means is that if the traverse rod

moves one way (say, to the left), the

machine ”wants to move to the right”.

The heavier and the faster the rod

moves, the more the machine ”wants

to move”, resulting in vibrations.

Here again, reducing the weight of the

traverse rod directly helps reducing

these vibrations.

26

SPINNOVATION No. 7

NOTE: Some new machines have the

two traverse rods move in opposite

ways. This induces the machine to

”want to twist around” instead of rock-

ing back and forth. This twisting is

generally less noticeable than the

rocking. The physical law (7) stands

unchanged, of course.

4. Extension of the Traverse Rod

Mill people have noticed that the

height of the packages at the far end

of the machine (away from the traverse

mechanism) is different from the

height near the mechanism.

The reason is that the traverse rod is

not a completely rigid body, but has

elasticity.

To understand what is going on, ima-

gine the following:

A coil spring is laying horizontally on a

table. The table is such that there is no

friction between the spring and the

table (say, the table is covered with

ice, or something like that).

You now take one end of this spring,

and slowly, VERY slowly move it back

and forth. The other end of the coil

spring will faithfully follow you slow

motion.

As you increase the speed of your

hand, the far end will no longer follow

the motion of your hand, but will do

some other motion. ( What exactly it

will do, depends on the motion of your

hand, and on the stiffness of the

spring: The stiffer the spring, the lon-

ger it will follow the motion of your

hand, as that speed increases).

EXACTLY the same thing is going on

with the traverse rod, your hand is

replaced by the traverse mechanism.

Again, the same rule applies: The stif-

fer the rod, the longer it will follow the

motion of the traverse mechanism

faithfully.

The stiffness is a function of the den-

sity of the material and the modulus of

elasticity

Stiffness = f (r, E) (8)

The CFR is much stiffer than a steel

rod, hence the extension is only 35% of

the extension of the steel rod, giving a

better package build at the far end of

the machine.

By now, one question must have come

to your mind:

All of this is so obvious, Newton found

his laws early in the 8th century, and

also carbon fibers have been around

for a while, why did not everybody use

CFR before?

The answer is that CFR have all the

above positive characteristics, but one

draw back: they are not very abrasion

resistant. (Those who play golf with CF

clubs know, that the golf bag leaves

marks on the CF shafts)

Therefore, the task was to find a

method to support the CFR on the

machine.

After several trials, SUESSEN found a

very good, yet simple method to attach

the CFR to the machine, avoiding the

problems with abrasion.

SUMMARY:

Carbon Fiber Traverse Rods have

many desirable properties:

– allow increase in delivery speed

– reduce load (hence wear) on the

traverse gear mechanism

– reduce vibrations of the machine

– improve package build

The one weakness has been over-

come with SUESSEN’s way of attach-

ing it to the OE machine.

(PST)

27

SPINNOVATION No. 7

NEWSNEWSNEWSMr. Martin Lutz Retired

With effect from December 200, Mr.

Martin Lutz, former Vice President

Sales of Spindelfabrik SUESSEN, has

retired. Mr. Lutz has provided valuable

assistance for the company’s deve-

lopment for more than 40 years. He

has been succeeded by Mr. Ioannis

Spiridopulos, his former assistant.

EliTeQCompactSet is a goer

Since ITMA Asia, Singapore, more than

200 ring spinning machines of differ-

ent make have been successfully

modernized with the new Compact

Spinning System. Most machines have

been follow-up orders of previously

installed test machines.

SUESSEN Brochures/Leaflets onCD ROM and in Internet

From ITMA Asia Singapore, SUESSEN

brochures, leaflets and Technical

Information pamphlets of the

SUESSEN Product Range are avail-

able as .pdf-files either from:

π our homepage

www.suessen.com/htmls/finfo.htm

or from

π our new CD ROM in English langu-

age, including some videoclips

concerning SpinBox SC Moderni-

zation and EliTeQCompactSet

To get your personal CD, please con-

tact our local agent or send an e-mail

directly to our marketing department

wa@suessen.com.

Change in theSUESSEN Management

At the end of 200, Mr. Hans-Georg

Frey, former Managing Director, left the

SUESSEN Group of Companies. We

wish him a successful and prosperous

future in his new employment with a

well-known German machine manu-

facturer.

See the STANDARDin Hairiness Testing

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