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How to use an automatic winding machine to improve production efficiency?

September 25,2023

The operational efficiency of automatic cone winders is a comprehensive indicator of the scientific use of these machines. It objectively reflects various aspects of work, such as the quality of yarn, the rationality of process parameters, the correctness of worker operating methods, and the adequacy of equipment maintenance. Currently, there is a significant gap in operational efficiency among enterprises using automatic cone winders due to differences in these areas. Well-utilized equipment can achieve production efficiencies of over 90%, while average enterprises range from 80% to 85%, and a few lagging companies have rates as low as 70% or even lower. The gap between advanced and backward enterprises in terms of production efficiency is about 20%. Therefore, to scientifically utilize automatic cone winders, it is crucial to focus on improving equipment production efficiency. Generally, it is expected that the production efficiency of automatic cone winders should exceed 85%.

This blog post will outline several key points to achieve this goal based on experiences and insights from various enterprises.

1. Enhancing Yarn Quality and Increasing Package Capacity:

Improving the quality of yarn by minimizing defects and ensuring proper shaping reduces unwinding and breakage during the rewinding process, thus increasing the operational efficiency. Additionally, increasing the package capacity can reduce knotting during winding. For instance, some cotton mills have increased their steel collar diameter from 38 mm to 42 mm when spinning yarn between 14.5 tex and 9.7 tex, resulting in a 25% to 30% increase in package capacity and a reduction of more than six knots per bobbin.

2. Setting Optimal Clearing Curves:

Analyzing yarn defects from electronic clearing indicates that 80% to 90% of defects are categorized as A- and B-class short thick places. Properly setting the clearance for these defects determines the number of cuts per 10,000 meters and influences the operational efficiency. Experimental results show that a cut count between 6 and 7 times achieves spinning rates of 85% to 86.5%, while increasing the cut count to 7.5 to 8 times decreases the spinning rate by about 2.0%. Therefore, three principles should guide the configuration of electronic clearing parameters: effectively removing harmful defects or foreign fibers, minimizing the removal of harmless defects or foreign fibers, and minimizing efficiency reduction due to clearing. Moreover, when using electronic clearers with foreign fiber detection functionality, it is essential to install detection devices during the opening and clearing process to identify most foreign fibers. This reduces the number of cuts for foreign fibers on automatic cone winders. 

Factories have conducted experiments and observed a 55% to 60% reduction in defect cuts and a significant improvement in production efficiency by installing foreign fiber removal devices during the opening process alone. Hence, relying solely on electronic clearing without additional measures is not advisable when dealing with raw cotton containing a significant amount of foreign fibers.

3. Strengthening Training for Machine Operators:

Automatic cone winders require skilled operators who are familiar with machine performance and understand the operation of various components. Therefore, it is crucial to provide training sessions of at least 20 hours for machine operators before they start working. Several factories have analyzed and found that the duration and proficiency of operator training have a significant impact on production efficiency. For example, an operator who has undergone more than 20 hours of training and has worked for over six months can achieve equipment efficiency above 85%. In contrast, another operator who received only six hours of training and rushed into work had an equipment efficiency of only 78% within two consecutive months. This demonstrates a 7% difference attributed to the variance in training. Therefore, operator training should not be overlooked.

4. Temperature and Humidity Control in the Winding Department:

Automatic cone winders have stricter requirements for temperature and humidity compared to regular winding machines due to their adoption of air splicing and electronic clearing technologies. Insufficient relative humidity in the workshop leads to yarn channel roughness, decreased cohesion, increased short defects, and unexpected defects. Therefore, it is essential to not only control the spinning process but also maintain proper ventilation and suitable temperature and humidity conditions during the winding process. The recommended temperature range is 22℃ to 30℃, while the relative humidity should be maintained between 62% and 72%. Particularly, when using capacitive electronic clearers, sensitivity to temperature and humidity changes increases, making proper control crucial to avoid excessive yarn breaks and cuts, which can affect production efficiency. Therefore, the notion that air conditioning equipment is unnecessary in the cone winding department is not comprehensive.

5. Rational Control of Automatic Winder Speed:

Automatic cone winders offer high speed and productivity, but excessive speed can increase the occurrence of hairiness. Conducting experiments while ensuring proper maintenance of critical components of the yarn pathway allows for controlling hairiness to a minimum. Under these circumstances, increasing the winding speed can maximize the production efficiency of automatic cone winders. For instance, Jiangsu White Rabbit Group achieved a 30% improvement in production efficiency by raising the winding speed from 1200 m/min to 1600 m/min while maintaining over 80 hairs above 3 mm per 10 meters of yarn for their production of 9.7 tex combed yarn. This exemplifies their meticulous maintenance work on various processes and quality control measures, paving the way for increased winding speed.

Conclusion:

To achieve optimal operational efficiency with automatic cone winders, enterprises should focus on improving yarn quality, optimizing clearing curves, providing comprehensive operator training, controlling temperature and humidity, and rationalizing machine speed. By implementing these measures, enterprises can enhance production efficiency and maximize the potential of automatic cone winders in the textile industry.

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