Increasing Speed of Yarn Spinning
Increasing Speed of Yarn Spinning
Increasing Speed of Yarn Spinning
TE 589A
Project
Vikram J Khona
Problem
The system is the ring-spinning machine. The
system consists of the spinning elements and
the accessories for assisting the spinning
elements. The fibers or filaments are given
twist to form the yarn. The yarn passes
through the traveller and gets wound on the
package. The traveller goes around the ring
inserting twist in the yarn, and there by the
yarn being formed.
The contradiction can be transformed into a physical contradiction, which is that if there should
be friction present so that the yarn is wound on the package but it should not be present as it
would heat up the traveller and wears it out.
Ideality
The ideal solution for this system would be that the yarn is formed at a high spindle speed say
100,000 rpm, which means high production and the yarn having excellent properties.
The ideal final result can be achieved by removing the harmful function which it the friction
created between the ring and the traveller. This can be achieved by making the ring and traveller
with a friction less material or by just eliminating the traveller.
It can also be reached by replacing a particular element of the spinning system. The traveller and
the ring can be replaced by some other mechanism where by the twist is inserted to the material
and the yarn being formed.
Contradiction Matrix
The contradiction present in this system is a technical contradiction. The contradiction matrix
can be used to resolve the contradiction.
Using the contradiction matrix there were about 3 parameters which most suited the
contradiction. They were;
Using the contradiction matrix the possible solution sets were determined and the best possible
suited principles were the principle 35.Transformation of physical and chemical state of the
object and 28.Replacement of the mechanical system.
The principle 35 says to change the state of the object, which can be changing the hardness,
density and/or surface finish of the ring and/or traveller.
The principle 28 says to change the mechanical system, which can be to change the mechanical
system to an electromagnetic system so that the friction between the ring and the traveller is
reduced.
Levels of Innovation
To find out which level of innovation this system is in at present, various factors of the
levels of innovation was considered. After considering the factors the system is in between level
3 and level 4.
Information
System name
The system name is the ring-spinning machine. The machine consists of the
spinning elements, which are the ring and the traveller and the auxiliary elements.
Primary function
The primary function of the system is to form yarn by introducing twist to the
material, which is either fibers or filaments.
Current or desired system structure
The system has the ring and traveller arrangement. The ring is mounted on a ring
rail, which is driven by a differential. There is a lappet through which the material
is guided to the traveller. The material flows from a package through guides and
passes through rollers.
Functioning of the system
The material is unwound from the package, which is placed on the back of the
package with tension. The material passes through guides and them to the back
roller and then to the front roller. The material is drafted between the two rollers.
The drafted material is then passes though the lappet and then to the traveller
which is mounted on the ring. The twisted yarn is then wound on another package
mounted on the spindle. The spindle is driven positively.
The spindle is rotating at around 25000 rpm. The yarn is passed through the
rollers and then guided down with the lappet and then passed though the traveller
and gets wound on the package. The traveller revolves around the ring
introducing twist. The traveller is negatively driven by the spindle.
System environment
The whole system interacts with the air, which surrounds the machine.
The system interacts with the operator
The system interacts with the other machines of same kind and other kinds
The system has a power source to run the motor
Previous attempts
There had been previous attempts made to improve the speed of the ring and
traveller system. These attempts have improved to an extent. The main difficulty
faced by these attempts is with the traveller burning out.
Other system that exhibit similar problems
Other systems that exhibit similar problem was not successfully identified.
The problem is the heat generated because of friction between the ring and the traveller is high
when the speed of the spindle is increased causing the traveller to burn-out.
The harmful function is the friction between the ring and the traveller creating heat, which
ultimately burns out the traveller.
The common element is the friction in both useful and harmful function.
Increase in production
Increasing spindle speed
Traveler heating up and wearing out
If the spindle speed is very fast then (+) the production is very high but (-) the traveller burns out.
Low production
Decrease in spindle speed
Traveler not heating up
If the spindle speed is low then (+) it reduces the production but (-) does not heat up the traveller.
1.11 Formulate the mini problem
The system is to make yarn by twisting the material, with the help of the ring and the traveller
where the traveller is driven negatively by the spindle.
IC-1: If the spindle speed is very fast then (+) the production is very high but (-) the traveller
burns out.
IC – 2: If the spindle speed is low then (+) it reduces the production but (-) does not heat up the
traveller.
The speed of the spindle should be high for producing the yarn fast and should be low to
eliminate the heating of the traveller due to friction
The separation principles are used and it can be resolved by separating the ring and the traveller
in space. This way there is no friction between the ring and traveller and the spindle speed can be
increased.
Very high speed of the spindle so that the production is willingly increased. This formulation
gives the importance of speed in production.
To produce yarn without the rotation of spindle. This is possible if only the traveller is driven
with another source and not form the spindle.
The speed of the spindle increases the speed of the traveller which increases the friction created
between the ring and the traveller.
Increase in production
Increasing spindle speed
Traveler heating up and wearing out
It is essential to introduce an resource which prevents the heating up of the traveller and
maintains the speed of the traveller.
The low speed of the spindle keeps the traveller cool, but does not increase the production.
Low production
Decrease in spindle speed
Traveler not heating up
It is essential to introduce a resource, which provides the traveller energy to have high speed and
the same time keeps the traveller from wearing out.
5.1 Render the initial SU-Field model for the problem on step 4.1
The SU-field model made with IC-1 is that the work piece is the ring in which the traveller is
placed. The tool is the traveller and the field created it the friction. It is a mechanical field. There
is a harmful relation ship between the work piece and the tool creating friction. There is a useful
and harmful relation ship between the traveller and the field friction as it is needed for winding
and not needed as it causes wear of the traveller.
5.2 Try to solve the problem with SU-Field model from step 5.1
In order to remove the harmful functions the 76 standard solution set was referred and the SU-
field model was solved. A field has to be added between the ring and the traveller to resolve the
harmful effect. A substance is added between the field created and the traveller to direct the
harmful function to an intermediate substance and thus the SU-field model is solved.
The substance that is added between the field (friction) and the traveller is a void substance. The
field added between the ring and the traveller is a electromagnetic field.
The operational time and the resource time could not be determined. But it is very short as the
speed of the machine is very high. It is in the terms of milliseconds.
The conflict present here is in between the ring and the traveller. The ring and the traveller come
in contact with each other in the inner surface of the ring as shown in the figure.
6.5 Mark useful, harmful, insufficient, and excessive substances, fields, properties, processes
and flows.
Harmful functions;
Generation of friction
Wearing of the traveller
In the MLP modeling we can see clearly what is going on in the zone of conflict. We can use the
smart little people to simulate the process. There are two groups of smart little people’s. The
SLP1 is the group in the traveller, and the SLP2 are the group in the ring. When the ring and the
traveller is in working the SLP2 and the SLP1 fight eachother killing the SLP1, causing the wear
of the traveller. This is because SLP1 are weaker than the SLP2.
The resources that is present in the system are ring, traveller, material, spindle, package, air,
waste fly, temperature, humidity, moisture, pressure, oxygen, balloon control rings, lappet, etc.
The x-resource should be able to pass the heat generated from the traveller to the environment.
The x-resource should be able to allow easy movement of the traveller around the ring.
The resources that are present in the system that can act as the x-resource is air and moisture
The x-resource can be a magnetic field that can repel the ring and the traveller so that there is no
contact between the ring and the traveller and thereby avoiding friction.
7.6 Try to find a trade-off solution of the problem with minimum deviations from IIR
requirements
The solution that can be achieved is that by using a electromagnetic field between the ring and
the traveller so that the ring and the traveller repels there by preventing them to come in contact
with each other.
7.7 Choose the main resource and formulate the enforced IIR
The main resource used here is a electromagnetic field. This is not an available resource. The
ring and the traveller can be oppositely charged preventing them to come in contact with each
other.
The x-resource should be present between the ring and traveller at all the time to prevent them to
contact each other to avoid heating, but it should not be present to provide some friction for the
yarn to wind in the package.
The contradiction in the process it that the friction created between the ring and traveller during
spinning causes heat and friction is also needed to wind the yarn in the package.
8.3 Formulate the fundamental contradiction for macro-state
The fundamental contradiction for flow is that the heat energy should flow to the environment
but should not pass to the rest of the traveller.
The x-resource should be of such properties that it should conduct heat to the ring from the
traveller but at the same time it should be viscous to provide some resistance to the movement of
the traveller in the ring.
The fundamental contradiction for process can be resolved by using a substance or a field that
has both the required properties.
The flow of the energy is resolved by suing a substance that transmits the heat energy form the
zone of conflict to the environment.
The additional resource should provide the necessary characteristics of the necessary x-resource
during the spinning process to prevent the heating up of the traveller.
The ideal final result of a process should be that there is no friction created to generate heat, but
there should be friction to wind the yarn in the package.
The ideal final result for flow is that it should transmit all the heat generated by the traveller to
the environment.
11.1 Solve new fundamental problem in IFR using resources discovered on step 6.4
11.3 Solve new fundamental problem in IFR using the final portrait of required problem
solving phenomenon
No need to solve.
No secondary problems.
Conclusions
The TRIZ tools were used to solve the problem of improving the productivity of ring spinning.
Ring spinning technology is very important and un-substituable until now. It has reached a
matured state. TRIZ tools were used to improve the system and the results are stated;
Change the hardness, density, material and/or the surface finish of the ring and traveller.
Use a field between the ring and the traveller. The field can be a magnetic field.
Use a void substance between the ring and the traveller. The substance could be air or
lubricant.
Suspend the ring in a electromagnetic field without the traveller, which gives the same effect
as a ring and traveller and there is no question about friction to hear up a traveller since there is
no traveller present.
These solutions are applicable either at present or in a future date. The last solution where in a
electromagnetic field is used to suspend the ring in space is a solution which can be achieved in a
future date as the present technology is not applicable.
Thus by using the TRIZ tools the solution of the problem is achieved with a higher level of
innovation.