1

Ring frame end breakage Distribution

N.Balasubramanian*
Retd. Jt. Director (BTRA) & Consultant
________________1__________________________________________________
Absract

Control of end breakage rate is the prime requirement for getting

better ring frame performance and for achieving higher spindle
speed. Repeated occurrence of end breaks in a few spindles often is
a source of higher end breakage rate. End breakage distribution is a
useful tool to detect and correct defective and disturbed spindles.
Deviation of actual distribution from theoretical becomes more
marked when spinning conditions are critical (high spindle speed or
over spinning). Yarn from spindles which give high repeated breaks
have a finer count. An improved method of testing significance of
end breakage by any action without being influenced by day to day
fluctuations is suggested. Examples are given to demonstrate the
superiority of this method
_____________________________________________________________________________
_

Control of end breakage rate at ring frame is the first step for
improving ring frame productivity. It not only leads to ends down
loss but also restricts spindle speed. Ends down denotes those
spindles where end has broken and is waiting for piecer to mend it.
Ends down loss is given by
d=e 0.75 t
Where,
d = ends down %
e = end breakage rate (breaks/100 spdl hrs)
1* Block I, Rajeswari, 36, 17th road, chembur, Mumbai 400071, 9869716298

t = patrol time of piecer in hrs

Further patrol time of piecer also increases with end breakage rate.
As a result ends down loss increases exponentially with increase in
end breakage rate as shown in Fig 1.

3.5

E
n
d
s
D
o
w
n

2.5

1.5

%
0.5

0
0

10

15

20

25

End Breakage rate (Breaks/100spl hrs

Fig 1 : Relation between Ends down% and end breakage rate
In addition if end breakage rate goes beyond manageable levels,
idle spindles will increase. Tenter (piecer) will make those spindles,
where breaks occur repeatedly, as idle.
Repeated occurrence of end breaks in a few spindles is often cited
as reason for poor ring frame performance. Ridgy build of bobbin, as
shown in fig 2, will be found on spindles where repeated end breaks
occur.

Fig 2 : Ridgy build caused by repeated occurrence of end breaks

Roller lapping also increases with increase in end breakage rate.

Since roller lapping involves higher time for mending, patrol time of
the tenter increases and results in more ends down%. Some studies
were therefore undertaken to find out the distribution followed by
end breakages under different conditions and compare it with
theoretical. An improved method for assessing the significance of
improvements in end breakage rate by any action is also proposed.

End Breakage Distribution

End breakage occurrence being a rare occurrence, distribution of
end breakage rate can be expected to follow Poisson distribution. In
actual practice distribution differs from Poisson due to variety of
reasons like 1.Variability in probability of breaks from spindle to
spindle, 2. Disturbances and defects in spindles 3. day to day
variability in mixing 4 disturbances in working of preparatory 5 Poor
maintenance 6. Variability inR.H. temperature. A study of

distribution of end breakage rate will provide useful clues in regard

to the quality of maintenance and process control.

Spindle Speed
Closeness of fit of end breakage distribution to Poisson depends on
conditions of spinning. End breakage distribution was determined
on 80s combed yarn on a ring frame spun on normal and 20% higher
spindle speed. Actual distribution was compared with Poisson in Fig
3 and 4 under these conditions. Actual distribution is close to
Poisson at normal spindle speed (Fig 3). When spindle speed is
increased not only end breaks increase but also departure from
Poisson is very marked. (Fig4). Another study was conducted by
over spinning the mixing to 100s and determining end breakage
distribution (Fig 5). End breakage distribution again deviates
markedly from Poisson in 100s. This leads to the inference that the
differences between spindles (in regard to probability of breaks)
becomes more pronounced when spinning conditions become
critical. This arises from disturbances in settings, defects in parts
and back material variations. The yarn spun on spindles with
repeated occurrence of breaks is found to be consistently finer in
count than that on spindles without breaks. High occurrence of end
breaks is because of lower yarn strength at the front nip in these
spindles because of finer count. So high count variation is one of the
reasons for repeated end breaks.

90
80
70

F
r
e
q
u
e
n
c
y

60
50
40
30
20
10
0
0

0.5

1.5

2.5

Number of end breaks

Fig 3 : 80 s Normal spindle speed

3.5

60

50

F 40
r
e
q
30
u
e
n
c 20
y
10

0
0

Number of end breaks

Fig 4 80s High Spindle Speed

40
35
30

F
r
e
q
u
e
n
c
y

25
20
15
10
5
0
0

Number of end breaks

Fig 5 : 100s Normal spindle Speed
End breakage distributions in well maintained and poorly
maintained ring frame sections on the same count and spindle
speed were determined and are given in Fig 6 and 7. Distribution as
per Poisson is also plotted. End breakage distribution deviates
markedly from Poisson in poorly maintained section (Section 1 Fig
7) . While no spindles give more than 4 breaks in section 2, as many
as 1.85% spindles give breaks more than 4 in section1. These
breaks obviously come from disturbances and defects in spindles,
rings and drafting system on these spindles. This shows that clues
to quality of maintenance can be obtained by comparing actual end
breakage distribution with ideal. Ring expert data system by Uster
is a useful attachment to ring frames as it gives spindle wise
distribution of end breakages. A sensor moves along the whole
length of the frame close to the traveler and detects without
contact movement of traveler. When an end has broken traveler will
not be rotating and will be detected by sensor as an end break. The

equipment gives end breakage rate distribution spindle wise and

indicates the rogue spindles which give repeated end breaks.
Similar online systems have been developed by other manufacturers
like Premier.

80
70

F
r
e
q
u
e
n
c
y

60
50
40
30
20
10
0
0

0.5

1.5

2.5

Number of end breaks

Fig 6. End breakage distribution in well
maintained section

3.5

4.5

F
r
e 40
q
u
e
n
c
y

0
0

Number of end breaks

Fig 7 : End breakage distribution in poorly
maintained section
Common causes for repeated end breaks a on a few spindles are
1. Ring frame defects and disturbances
2. Preparatory deficiencies
Ring Frame defects
1. Disturbed spindle centering is one of the major causes of
repeated occurrence of
end breaks. This arises because
1.spindle centering schedule is not followed strictly 2. Proper
gauges and lighting is not available. Painting top of the gauge white
and use of a portable light help to improve accuracy. Electronic
spindle gauge can help to reduce subjectivity but requires training.
3. Vibrating spindles and bobbins
4. Worn out rings, spindles and lappets
5. Defective cradle retention spring. Cradle stays in a lifted
condition resulting in poor control over fibres.

10

6. Low top roller pressure, This can arise from worn out hose pipe
or plunger or disturbed height setting.
7. Missing bottom apron. Sufficient number of spare aprons
should be kept in each staff to facilitate prompt replacement of
broken apron.
Defects and disturbances in preparatory
Long thin places in roving due to sliver splittiing in the creel or
partial lapping on roller at speed frame and draw frame.
Disturbed working in preparatory like roller lapping or
frequent breaks.

Proposed Method to estimate improvement

High day to day and time to time within a day variability in

end breakages comes as a major impediment in drawing
definite conclusions about any actions taken. Proper
methodology to be followed in designing experiments to
assess improvements in end breakages from any action is first
discussed. An improved statistical test which will help to
detect differences to a greater accuracy without being affected
by day to day variations is proposed. Examples are given from
actual studies to explain this method and bring home its
usefulness in interpretation of results. Though the discussion
has been restricted to ring frame end breakages, the same
principle will hold for breakages in other processes as well.
Experimental Design
The two sources of variability in end breakages that should be
taken into account while designing experiment are 1. Day to
day and shift to shift variations 2. Machine to machine
variations. It is therefore imperative that the two parameters
or materials to compared are allowed to run on a pair of ring
frames side by side and simultaneous study of end
breakages is taken to cover all doff positions more than once.
Machine difference can be taken care of by interchanging the
variables between the machines. An even better method for
overcoming the machine effect is to carry out the experiments
on more than one pair of machines.
Analysis of Results
To facilitate statistical analysis, the results are divided into
units, each of one day or shorter duration. In the usual

11

method, standard deviation and standard error are estimated

from the unit test results, from which standard error of
difference is calculated. This method has the drawback that
this overestimates the variability in difference of end
breakages because of day to day to variations. Day to day
fluctuations not only increase variability of end breakages but
also causes the breaks in the two experimental set ups
( normal and modified) to move up and down in unison. The
difference in end breakages on the other hand is not affected
to the same extent by day to day variations.
A better method under such conditions would be to calculate
the difference in end breakage rate for each unit test and
estimate the standard deviation and standard error of the
same and check the average difference against this to find the
significance. Even if statistical test is not done, such a method
will show from visual examination the likelihood of the
difference being real. If the difference in unit tests is of the
same sign in most of the tests, the difference is more likely to
be a real one and not a chance one.
The following examples will help to substantiate the merit of
this method
Ring Cleaning
Ring frame performance gets affected by deposition of wax,
fly, dirt and metallic substances over a period of working and
ring cleaning at periodic intervals is suggested to overcome
this. To assess the improvements from ring cleaning 2 ring
frames were chosen. Rings on one side of each frame was
cleaned while no action was taken on rings of other side.
Simultaneous study of end breakages was done on cleaned and
normal side of ring frames for a period of 9 days, with 3 hours
study each day. The average end breakage rate for the two
sides for the 9 days are given in Table 1 and Fig 8
Table 1: Reduction in end breakage rate by ring cleaning
(Breaks/100spl hrs)
Day No
1
2
3
4

Ring cleaned,
x
11.0
9.3
7.7
8.8

Normal(withou
t cleaning), y
13.3
10.4
11.4
12.8

Difference
y-x
2.3
1.1
3.7
4.0

12

5
6
7
8
8.5
Average

7.5
7.9
7.9
7.7
8.5
8.48

8.5
11.6
8.0
10.2
10.0
10.69

1.0
3.7
0.1
2.5
1.5
2.21

Standard deviation(SD), Standard error(SE), t value and confidence

level of significance are given in Table 2

Table 2
Test of significance
Normal Method
Variance

x = 1.248
2y =
3.179
2

Improved method

2y-x = 1.924

Standard error of
( yx) 2
( x ) 2+ ( y ) 2 =0.701

=0.462

difference
9
9
t=
3.15
4.78
Difference/Standard
error of difference
Correlation Coefficent
0.628
r between x and y
In the normal method, SD of breakage rate for cleaned and
normal sides are calculated separately from which SE of difference
was estimated. In the improved method, difference in breakage rate
between sides for each day is computed from which SD and SE of
difference is calculated. t value for each method is calculated and
is given in last row. SE of difference of a lower order and t value of
higher order is found with improved method compared to normal
method. As a result, reduction in end breakages by ring cleaning
comes out to be significant at a higher level of confidence limit with
the improved method. This is because day to day variations in ring
frame performance affect cleaned and normal sides equally. As a
result, end breakage rate on both sides move up and down in
unison. On days when ring frame performance is poor, both sides

13

tend to give a higher breakage rate. This will be amply clear from
Fig 8.
E 14
n
d
12

B
r
10
e
a
k
8
s
/
1 6
0
0
4

s
p
l
h
r
s

0
0

10

Day No

Fig 8 Comparison of end breakage rates with ring cleaned and

normal sides
It is well known that

(y-x)2 = x2 + y2 2 x y r
where y-x = Stabdard deviation of difference y-x
x = Standard deviation of x
y = Standard deviation of y
r = Correlation coefficient between x and y
Since a positive correlation exists between x and y, (y-x)2 is lower
than (x2 + y2). The positive correlation is because day to day
fluctuations in breakage have equal influence on x and y. When

14

values of x, y and r are substituted in the above equation, a value

for y-x in agreement with that by improved method is obtained.
Better Carding
In the 2nd example, carding quality was improved on selected card
by increasing cylinder and lickerin speeds. The material was
channelized separately and creeled on one side of 2 ring frames
with other side working with normal material. End breakages were
compared on the 2 sides for 10 days with 3 hrs study each day. The
results are shown plotted in Fig 9.
E 20
n
d 18
b
r
e
a
k
s
/
1
0
0

16

s
p
l

h
r

14
12
10
8
6

10

12

Day No

Fig 9 Improvement in ring frame end breakages by higher cylinder

lickerin speed in card
Fig 9 shows that not only end breakages are reduced by higher
cylinder and lickerin speed but also that end breakages by the two
set ups go up and down in unison

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Standard deviation(SD), Standard error(SE) and t value are given

for the end breaks with normal and improved carding are given in
Table 3.

Table 3
Test of significance
Normal Method

Variance
Standard error of
difference
t=
Difference/Standard
error of difference
Correlation
coefficient r between
x and y

2
x

Improved method

= 3.06
2y = 4.18

( x ) 2+ ( y ) 2 =0.851

2y-x = 2.16
( yx)2

=0.465
10
7.29

10
3.98

0.710

Standard error of difference is lower and t value higher by the

improved method compared to normal method. Once again this is
because of the high positive correlation between end breaks for the
two carding conditions.
Make of Ring frame
Third example compares the end breakage rates in two makes of
high speed ring frames fed by the same back material. Comparison
of breakages rates over a period of 10 days is shown in fig 10

16

E
n
d

16

B
r
e
a
k
s
/
1
0
0

12

s
p
l

14

10
8
6
4
2
0
0

10

12

Day No

h
r
s
Fig 10 : Comparison of end breaks in two makes of Ring frames.
Standard deviation(SD), Standard error(SE) and t value are given
for the end breaks between two groups of ring frames in Table 4.
Table 4
Test of significance
Normal Method, x

Variance

2
x

Improved method, y

=0.548
2y =

2y-x =1.398

2.473
Standard error of
difference
t=
Difference/Standard
error of difference
Correlation
coefficient r between

( x ) 2+ ( y ) 2 =0.550

( yx) 2

=0.374
10
2.51

10
1.71

.697

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x and y
Fig 10 shows that end breakage rate is lower on ring frame make II
on all but one day. Table 4 once again demonstrates the superiority
of improved method in bringing out the significance of between the
2 makes, which is of finer order The difference between the two
makes is statistically significant only when improved method is
used.
Measures for controlling end breakages in ring frame have been
covered in earlier articles1,2

Conclusions
1. Control of end breakages is the prime requirement for keeping
down efficiency losses and for achieving higher spindle speed.
Repeated occurrence of end breaks in a few spindles is one of
the major causes of high end breakage rate. End breakage
distribution is a useful tool for detecting defective/disturbed
spindles which give high breakages. By taking corrective
action on such spindles, overall ring frame performance can be
improved. Extent of departure of distribution from theoretical
(Poisson) indicates the scope for process improvement. Online
monitoring systems like Uster Ring data are useful in detecting
spindles giving repeated end breaks.
2. Deviation of end breakage distribution from theoretical
(Poisson) becomes more marked when spinning conditions are
critical (high spindle speed or overspinning)
3. An improved method for checking significance of difference in
end breakage rate brought about by any action is suggested.
This method is less affected by day to day and shift to shift to
shift fluctuations in breakages rates and brings out finer order
of differences. Examples are given to demonstrate the
superiority of this method
References
1. N.Balasubramanian, Measures for improving yarn quality
and productivity, Indian Textile J, 1995, zaMarch, p20
2. N.Balasubramanian and V.Y. Chaudhary, Improvements in
Ring frame perfoformance and productivity by frequency
invertor drive, Indian Textile J, 1994, Nov, p14