short staple manual€¦ · pes, cv, blends and pac 25 spinning of synthetic ﬁbres pes, pac and...

Short Staple Manual

06 Introduction

08 Travellers

09 Designation of the ring traveller parts10 Finishing treatments11 Wire cross sections12 Delivery program flange 113 Delivery program flange 1/214 Delivery program flange 215 Delivery program for ORBIT and SU16 Traveller weights17 Traveller weights for T-flange, ORBIT and SU18 Comparison chart – flange travellers19 Setting of the traveller cleaner – flange 1/2 and flange 120 Setting of the tangential traveller cleaner – flange 1/2 and flange 121 Setting of the traveller cleaner – flange 2

22 Application recommendations

23 Recommendation for Bräcker travellers – cotton24 Recommendation for Bräcker travellers – PES, CV, Blends and PAC25 Spinning of synthetic fibres PES, PAC and blended yarns26 Spinning of compact yarns27 Spinning of slub yarns28 Spinning of soft core yarns29 Spinning of hard core yarns

60 Performance and spinning quality

61 Technical spinning information 61 Yarn breaks 62 Yarn breaks during spinning process 64 Yarn breaks during doffing 65 Hairiness 67 Neps 68 Numbering systems for yarns and twists 70 Traveller speeds / performance calculations

72 Tools

73 ROLSPRINT, SECUTEX, CUTEX, CLIX, OUTY 74 Traveller inserting tools – RAPID and BOY 78 Magazining system

80 BERKOL® cots and aprons

81 Cots 86 Aprons

88 BERKOL® maintenance machines

89 Presses 90 Grinding technologies 92 Grinding machine BG/U 500 94 Grinding machine supergrinder 96 Berkolizer 97 The surface treatment: berkolizing 98 Testing device 99 Surface finish measuring device 100 Shore hardness testing device 101 Lubrication devices

30 Lubrication of ring / traveller system

31 Yarn clearance34 Examples of traveller positions35 Motions of the ring traveller

36 ORBIT and SU ring / traveller system

37 ORBIT application38 Travellers for ORBIT rings39 Traveller wear and tear40 SU application41 Travellers for SU rings42 Setting of the traveller cleaner43 Setting of the tangential traveller cleaner

44 Rings

45 Designation of the ring parts46 Finishes and treatments47 Ring profiles48 Ring shapes49 Ring holder assembly system50 Fixing methods 51 Application matrix53 Requirements for optimal results54 Start-up proceeding55 Ring load56 Traveller wear, insufficient lubrication57 Ring life time58 Wear and tear on rings

54

Index

Our customers get the profit

Swiss technology, know-how and service is transformed into hard cash for our customers.Our legendary Bräcker manual shows you how you can increase your benefit with Bräckerproducts, technology, know-how and service.

The manual contains information on:

Bräcker products and technology• Leading-edge technology for key components in spinning mills.• Development and manufacture of specific, high-grade, innovative products.

Bräcker know-how• Our distinctive know-how in technology and components, developed and perfected over decades.• Competence in consulting and solution-finding, thanks to extensive market knowledge and a wide background of experience.

Bräcker service• Our wide range of top-quality products for any application.• The right solution for every yarn quality, with key components which are optimally matched to one another.

The result is a consistent increase in quality and productivity for you as a Bräcker customer.

We are looking forward to being a partner for your business.

Bräcker – Enjoy Performance!

76

Company

Founded in 1835 as a family business, Bräcker AG soon developed into a specialist for key products in the textile industry. With the expansion to France in 1951, the foundation stone was laid for success-ful international development.

Thanks to steadfast opening up of new markets early on, in particular overseas, Bräcker AG became a global market leader. A demanding, responsible position which regularly confirms the innovative strength and market flair of Bräcker AG, but which also proves to be a strong challenge. Bräcker provides a solid foundation of knowledge and market overview, firmly supporting and confirming the exceptional position in the markets. And this development continued successfully with the take-over of the BERKOL Business Unit in December 2007.

Enjoy Performance

Uncompromising quality standards and extensive industry knowledge make Bräcker the market leader in the manufacture and marketing of key components for ring spinning machines. This is evident not only in the wide range of excellent products but also in the distinctive competence of the staff to advise and provide solutions.

Thanks to leading-edge technology and innovative components manufacturing, we as a quality-certified company, guarantee with our products maximum production capacity together with maximum operational reliability. Through constant monitoring, we ensure optimal quality consistency in our production.

The profound knowledge of technology and components gathered over decades is continuouslyenhanced and perfected. Our staff has many years of industry knowledge, giving you as a customer the certainty that the optimal products will be specified for your specific requirements.

As a Bräcker customer you can benefit from fast and direct access to a worldwide sales, consultancy and service network – and you can rely on a competent partner as your contact person. The representatives are a part of your particular country‘s culture and they are in constant contact with the main office. So the knowledge gained in practice flows continuously into innovating products and services.

The Bräcker advantages in a nutshell: consistent increase of profit and success for your company!

Introduction

Bräcker ProductsSwiss Premium Quality

98

Designation of the ring traveller parts

Travellers TravellersDesignation of the ring traveller parts

C-shaped travellers

1 Inner traveller width2 Height of bow3 Yarn passage4 Wire cross section5 Traveller - ring contact surface6 Angle of toe7 Toe8 Opening9 Upper part of traveller bow

2

1

3

5

8

9

6

7

4

The Bräcker steel traveller is one of the key components in ring spinning and twisting of coarse and fine yarn counts as well as compact yarns. Many years of experience in developing and manufacturing travellers within the narrowest tolerances are the base for the many advantages of Bräcker travellers made in Switzerland.

Travellers

1110 Travellers TravellersDesignation of the ring traveller parts Designation of the ring traveller parts

Wire cross sections

The wire cross section influences the yarn quality, the running behaviour, the performance and the life time of the travellers. The right choice of the wire cross section is an important factor for optimal results.

f-flat For cotton, viscose and blends.Helps to reduce hairiness.For average spindle speeds.

dr-half round Synthetics and blends: prevents fibre damage.Fine cotton yarns: reduces neps.Often used for core- and slub yarns.

udr-ultra half round For cotton and blends: Through an enlarged contact surface on the ring raceway, highest performances are possible.Most used wire cross section.

fr-flat/round For Core yarns with Polyester Core, Acrylics and delicate fibres.f-profile at the toe improves the ring contact.r-profile for fibre protection in the yarn passage.

drh-half round highSpecial profile for SU travellers. Application for Viscose and Polyester.

Finishes and treatments

Travellers with an additional finish show the following advantages:• Higher traveller speeds• Longer traveller life• Improved running behaviour and as a result a more consistent yarn quality• Rust/oxidation protection (especially STARLET)

SAPHIRDiffusion treatmentBräcker SAPHIR has been especially developed for high performances. The enrichment components are present throughout the entire traveller cross section and do generate their effect even when the surface is worn.

STARLETElectrolytic surface treatment (special nickel plating)A nickel coating is applied with a special process.Low friction values in the yarn passage prevent fibre damages. Optimum resistance to corrosion.

PYRITPYRIT travellers have an enriched steel structure by applying additional components. The wear resistance is considerably improved. This improves the running behaviour and guarantees a more consistent yarn quality. At high speeds the traveller service life can be increased by more than 100% compared to travellers with conventional finish.

ZIRKONSteel traveller with ceramic coatingThe HiTech coating with outstanding properties for highest performance combined with long life.Especially designed for compact spinning on highest speeds.Traveller life up to 1’000 hours and more.ZIRKON travellers are only to be used on TITAN rings.

ISO No.

1312 Travellers TravellersTraveller delivery program for flange rings Traveller delivery program for flange rings

Flange 1/2Flange 1

Traveller delivery program for flange rings

Traveller Shape Wire crosstype section

C 1 SKL udr

C 1 SEL udr

C 1 EL udr

dr

EL 1 f

C 1 SL udr

dr

L 1 udr

f

C 1 UL udr

f

M 1 udr

dr

f

EM 1 udr

dr

f

C 1 UM udr

C 1 LM udr

C 1 MM udr

C 1 HW dr

EM 1 fr

C 1 SM fr

C 1 SH fr

12 11 10 9 8 7 6 4 3 2 1 1/0 2/0 3/0 4/0 5/0 6/0 7/0 8/0 10/0 11/0 12/0 14/0 16/0 18/0 19/0 20/0 22/0

200 180 160 140 125 112 100 90 80 71 63 56 50 45 40 35 31 28 25 22 20 18 16 14 12 11 10 9

29/0

26/0

18

22

16

16

Delivery programMost recommended


C 1/2 EL udr

C 1/2 UL dr

C 1/2 UM udr

C 1/2 EM f

2/0 3/0 4/0 5/0 6/0 7/0 8/0 10/0 11/0 12/0 14/0 16/0 18/0 19/0 20/0 22/0 24/0 26/0 28/0

Example for placing an order:An order should include the following specifications:

Traveller shape Wire cross section Finish Packaging Traveller No. Quantity in 1'

Example: C 1 MM udr SAPHIR AP 71 100


Traveller No.

50 45 40 35 31 28 25 22,4 20 18 16 14 12 11 10 9 8 7.1 6.3

Traveller No.

ISO No.

1514 Traveller delivery program for flange rings Traveller delivery program for ORBIT and SU rings

ORBIT SFB 2.8Flange 2

Traveller delivery program for ORBIT and SU rings


M 2 udr

dr

f

EM 2 dr

C 2 UM udr

C 2 MM dr

H 2 dr

f

fr

EH 2 dr

C 2 HW dr

C 2 f

20 18 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1/0 2/0 3/0 4/0 5/0 6/0 7/0 8/0 9/0 10/0

12/0

36

26

36


SFB 2.8 RL dr

SFB 2.8 PM udr

dr

125 112 100 90 80 71 63 56 50 45 40 35 31 28 25 22 20 18 16

ISO No.

14 12


SU-B drh

r

SU-BF udr

SU-BM drh

400 355 315 280 250 224 200 180 160 140 125 112 100 90 80 71 63 56 50

ISO No.

45 40 35 31 28



SU

ISO No. 355 315 280 265 250 224 200 180 160 140 125 112 100 95 90 80 71 63 56 50 45 40 35 31 28 25 24 22

Traveller No.

Travellers Travellers

Example for placing an order:An order should include the following specifications:

Traveller shape Wire cross section Finish Packaging Traveller No Quantity in 1'

Example: C 2 MM dr SAPHIR AP 125 100

1716 Traveller delivery program for ORBIT and SU rings Traveller delivery program for ORBIT and SU rings

Traveller weights for T-flange, ORBIT and SU

The traveller weights are determined not only by the yarn count but also by the following parameters:

Fibre type Synthetics, Blends 1-2 number heavier travellers

Spindle speed Higher RPM Lighter travellers

Spinning geometry• Small ring diameter Small balloon Lighter travellers• Large ring diameter Large balloon Heavier travellers• Short tube length Small balloon Lighter travellers• Long tube length Large balloon Heavier travellers• Spinning without anti balloon ring Control of the balloon Heavier travellers

Traveller weights

The traveller has to balance the yarn balloon. Because the balloon varies from bottom to top of the cop in large scale, the traveller on the bottom of the cop is rather too light, on the top too heavy. Choosing the correct traveller weight is always a compromise.

Measuring the yarn tension on ring spinning frame is not practicable. The best method is to judge the balloon shape. This can be done by a stroboscope but also with a flashlight.

Insert travellers of two to three consecutive Nos. (weights) after doffing on a few spindles and observe the balloon.

1 Select the traveller weight at base of cop when the bobbin reaches full diameter (Fig 1)

2 Balloon should not touch: • Separators • Tip of tube • When using anti-ballooning rings, lower part of balloon should be slightly bigger in diameter than upper part

3 Balloon should not collapse (double ballooning)

4 When shape of balloon is stable, traveller weight is correct

5 Check balloon at full cop (Fig 2): • Balloon should not be too straight

6 Check yarn quality with selected traveller weight

Fig 1: Cop base with full cop diameter Fig 2: Full cop

10 6 12 - 16 200 - 280 250 - 315 14 8 10 - 14 160 - 250 250 - 315 200 - 280 17 10 8 - 11 125 - 180 224 - 280 140 - 200 20 12 6 - 10 100 - 160 90 - 125 160 - 250 100 - 160 24 14 3 - 7 80 - 112 80 - 112 125 - 224 90 - 140 27 16 1 - 4 63 - 90 71 - 100 112 - 180 80 - 112 34 20 2/0 - 2 50 - 71 56 - 80 71 - 140 63 - 80 40 24 3/0 - 1 45 - 63 45 - 63 63 - 125 50 - 71 50 30 6/0 - 2/0 31.5 - 50 31 - 50 56 - 112 35.5 - 63 68 40 9/0 - 5/0 23.6 - 35.5 22.4 - 35.5 50 - 71 31.5 - 56 85 50 10/0 - 6/0 22.4 - 31.5 20 - 31.5 45 - 63 100 60 14/0 - 9/0 16 - 23.6 18 - 25 40 - 50 135 80 18/0 - 12/0 12.5 - 18 14 - 20 170 100 19/0 - 14/0 11.2 - 16 200 120 20/0 - 18/0 10 - 12.5 240 140 22/0 - 19/0 9 - 11.2

Nm Ne T-flange ORBIT SU

PES/Blends

ISO

PAC and CV

ISOISOTraveller No.

T flange ORBIT SU

The values mentioned above are guiding values.The final traveller number should be selected through trials.


1918 Traveller delivery program for ORBIT and SU rings Setting of the traveller cleaner

Setting of the traveller cleaner

Comparison chart flange travellers

The international standard ISO 96-1 for travellers specifies the traveller weight in an even percentilegrading according to the ISO R20 series.

Traveller weights in mg resp. per 1’000 travellers in g

Conv.Traveller

No

ISO No, respectively traveller weight in mg Traveller

BräckerISO

R&F Type Profile ≤ 9/0 8/0 - 4/0 3/0 - 3 4 - 10 11 - 16Carter Kanai *

30/0 29/0 5.6 28/0 6.3 5.0 6.3 26/0 7.1 6.0 7.1 24/0 8.0 7.1 8.0 9.5 22/0 9.0 8.0 9.0 10.9 20/0 10.0 9.0 10.0 12.2 19/0 11.2 10.0 11.2 12.9 18/0 12.5 11.2 12.5 13.5 17/0 (13.2) 11.8 13.2 14.3 16/0 14.0 (13.2) 14.0 15.3 15/0 (15.0) 14.0 15.0 16.4 14/0 16.0 (15.0) 16.0 17.8 13/0 (17.0) 16.0 17.0 20.0 12/0 18.0 18.0 18.0 21.6 11/0 20.0 (19.0) 20.0 23.2 10/0 22.4 20.0 22.4 25.0 9/0 (23.6) 22.4 23.6 26.8 8/0 25.0 (23.6) 25 28.5 7/0 28.0 26.5 28 30.2 6/0 31.5 30.0 31.5 32.2 5/0 35.5 31.5 35.5 35.1 4/0 40.0 35.5 40 38.3 3/0 45.0 40.0 45 42.2 2/0 50.0 45.0 50 48.3 1/0 56.0 50.0 56.0 54.6 1 63.0 60.0 63.0 62.2 2 71.0 71.0 71.0 73.6

C ½ EL udr 1.6 1.6C ½ UL dr 1.6 1.6C ½ UM udr 1.6 1.6C ½ EM f 1.6 1.6 1.6C 1 SKL udr 1.8 1.8C 1 SEL udr 1.8 1.8C 1 EL / EL 1 f, dr, udr 1.9 2.1 2.1C 1 SL dr, udr 1.8 1.8 2.1L 1 f, udr 1.6 2.0 2.1C 1 UL f, udr 1.8 1.8 2.1 2.3M1 r, dr, udr 1.9 2.1 2.2 2.6

EM 1 f, dr, udr 1.9 2.1 2.2 2.6 3.0

fr 2.7 2.7 3.0C 1 UM udr 1.7 1.7 1.9 2.2C 1 LM udr 1.9 2.1 2.3 2.5C 1 MM udr 1.9 2.1 *1) *2 ) *3 )

C 1 HW dr 3.7 4.0 4.0C 1 HW dr 4.0 4.0C 1 SH fr 3.7 4 4.1 5.2

16.0 Example: Travellers with the same weight may have different conventional traveller numbers, depending on traveller brand.

The weight increases from number to number by 12.5%: 100 + 12.5% + 12.5% + 12.5%...

Exceptions (in brackets): Series R40 = 100 + 6.25% + 6.25% + 6.25%...

Bräcker travellers are produced in accordance with ISO 96-1.

Conv.Traveller

No

ISO No, respectively traveller weight in mg

BräckerISO

R&F Carter Kanai *

3 80.0 80.0 80.0 81.0 4 90.0 85.0 90.0 87.7 5 (95.0) (95.0) 95.0 (95.3) 6 100 106 100 109 7 112 112 112 122 8 125 125 125 136 9 140 140 140 154 10 160 160 160 175 11 180 180 180 204 12 200 200 200 224 13 224 224 224 244 14 250 (236) 250 (264) 15 (265) 250 265 283 16 280 (265) 280 (297) 17 (300) 280 300 311 18 315 (300) 315 324 19 (335) 315 335 337 20 355 325 355 351 22 (375) 355 375 377 24 400 385 400 404 26 (425) 415 425 431 28 450 450 450 456 30 (475) (475) 32 500 34 (530) 36 560 38 (600) 40 630

Flange ½ and flange 1

• Under no circumstances should the traveller touch the cleaner (yarn breaks, ring damage).• By application of different traveller types and/or numbers, the largest value should be set.

b

*1) No 1 - 6 = 2.6*2) No 7 - 10 = 3.0*3) No 13 - 22 = 3.5

b

* main types

Traveller No.

≤ 23.6 25 - 40 45 - 80 90 - 160 180 - 280ISO No.


ISO No.

2120 Setting of the traveller cleaner Setting of the traveller cleaner

Traveller

Type Profile ≤ 11/0 10/0 - 4/0 3/0 - 3 4 - 10 11 - 14 16 - 20 22 - 36

M2 f, dr, udr 1.9 2.1 2.2 2.4EM 2 dr 2.2 2.4 2.8C 2 UM udr 1.7 1.9 2.1C 2 MM dr 2.4 2.4 3.0 3.3 3.3

H2 f, dr 2.2 2.6 3.0 3.3

fr 3.0 3.0 3.5 3.6EH 2 dr 2.4 2.8 3.1 3.3 3.6C2 HW dr 3.0 3.2 3.3 3.4C 2 f *1) *2 ) *3 ) *4 ) *5 )

Flange ½ and flange 1 Flange 2

Tangential traveller cleaner (flange 1, udr, dr and f profile only)

• Suitable for high speed travellers• Recommended for all compact spinning processes• Advantages: more efficient cleaning of the traveller, prevention of fibre accumulation• Important: the tangential traveller cleaner must be installed with a distance h = 4.5 mm to the flange crown

• Under no circumstances should the traveller touch the cleaner (yarn breaks, ring damage).• By application of different traveller types and/or numbers, the largest value should be set.

b

*1) No 1 - 6 = 2,1*2) No 7 - 9 = 2.7

b

h

b

*3) No 10 - 18 = 3.1*4) No 20 - 28 = 3.8

b

h

Traveller No. 12/0 - 4/0 6/0 - 8 3 - 36

Distance b 2.8 3.3 4.1

Tangential traveller cleaner (flange 2, udr, dr and f profile only)

• Suitable for high speed travellers• Recommended for all compact spinning processes• Advantages: more efficient cleaning of the traveller, prevention of fibre accumulation• Important: the tangential traveller cleaner must be installed with a distance h = 4.5 mm to the flange crown

Traveller No. 26/0 - 11/0 16/0 - 6/0 8/0 - 1 3/0 - 6 4 - 12

Distance b 1.8 2.0 2.2 2.4 2.8

Traveller No.*5) No 30 - 35 = 5.0

Flange 2

ISO No.

ISO No.

7.1 - 20 14 - 31.5 25 - 63 45 - 100 90 - 200

≤ 20 22.4 - 40 45 - 80 90 - 160 180 - 250 280 - 355 375 - 560

18 - 40 31.5 - 125 80 - 560


2322 Application recommendations Application recommendationsRecommendation for Bräcker travellers

Fibre

Yarn count range Ne 6 - 16 Ne 14 - 34 Ne 30 - 50 Ne 40 - 80 Ne 60 - 140

Flange ½ C ½ UM udr C ½ UM udr C ½ UM udr C ½ EL udr C ½ EL udr

C ½ EM f C ½ UL dr C ½ EM f C ½ EM f C ½ UL dr

Flange 1 M1 / EM1 dr C1 MM udr C1 MM udr C1 UL udr C1 EL dr C1 MM udr M1 / EM1 udr C1 UL udr C1 MM udr C1 UL udr C1 HW dr C1 UM udr C1 LM udr C1 EL udr C1 SL dr/udr C1 UM udr C1 LM udr M1 / EM1 udr C1 SL dr/udr C1 SEL udr

M1 / EM1 udr M1 / EM1 dr C1 SL udr / dr EM1 udr L1 f C1 UL udr C1 EL udr L1 f EL1 f M1 f / EM1 f C1 UM udr EL1 f UL1 f M1 f / EM1 f L1 udr L1 udr

Flange 2 C2 HW dr C2 MM dr H2 / EH2 dr EM2 / M2 dr C2 MM dr EM2 / M2 dr H2 dr / EH2 dr H2 f C2 UM udr M2 f

ORBIT SFB 2.8 PM udr SFB 2.8 RL dr SFB 2.8 PM dr SFB 2.8 PM udr

SU

Cotton

Recommendations for Bräcker travellers for T-flange, ORBIT and SU rings

Travellers in bold prints are mostly used

The best performance can be achieved by selecting thecorrect Bräcker traveller type. Traveller shape, wire crosssection, weight and finish have a significant impact on the productivity of a ring spinning machine and the yarnquality. The following charts are a guideline for the correct selection of Bräcker travellers.

Application recommendations

2524 Recommendation for Bräcker travellers Spinning of synthetic and blended yarns

Fibre

Yarn count range Ne 6 - 16 Ne 20 - 60 Ne 6 - 40

Flange ½ C½ EM f C½ UL dr

Flange 1 M1 / EM1 dr C1 MM udr C1 SM fr C1 HW dr M1 / EM1 udr M1 / EM1 dr C1 MM udr C1 LM udr C1 HW dr C1 UM udr C1 UM udr EM 1 fr

C1 LM udr M1 / EM1 dr C1 SH fr EM1 udr C1 UL udr M1 / EM1 udr C1 SL dr

Flange 2 H2 / EH2 dr M2 / EM2 dr H2 / EH2 dr C2 HW dr C2 MM dr H2 fr

C2 MM dr H2 / EH2 dr C2 MM dr M2 / EM2 dr C2 UM udr C2 UM udr

ORBIT SFB 2.8 PM dr SFB 2.8 PM udr

SU SU-B drh SU-B drh SU-BM drh SU-BM drh SU-BF udr SU-B drh

SU-BM drh SU-BF udr

Polyester / Viscose / Blends

Recommendations for Bräcker travellers for T-flange, ORBIT and SU rings

PAC / Blends

Traveller in bold prints are mostly used

Spinning of synthetic (PES, PAC) andblended yarns

Fibres made from synthetic polymers have different characteristics. Most of these fibres are sensitive to heat and mechanical damages. Therefore the instructions of the fibre producer have to be followed.

The traveller speeds are limited due to following reasons: Spinning with excessive traveller speeds can cause thermal fibre damages which are onlyvisible after the dyeing process.

Dyed or dull fibres often contain abrasive compo-nents which can reduce the service life of travellers and rings.

Rings:TITAN flange 1 and 2 rings are recommended for the entire range of application. THERMO 800 flange 1 and 2 rings can be used for lower spindle speeds.

The ORBIT flange ring has the advantage of a large ring / traveller contact area this helps to avoid thermal damages at higher traveller speeds.

The SU flange rings with a large ring / traveller contact area are recommended for coarse to medium counts.

Travellers:To avoid fibre damages higher bowed travellers with a dr or fr profile can be used.

Traveller finishes and treatments:STARLET or PYRIT can help to increase the traveller life under critical conditions, SAPHIRfor normal conditions.

Traveller recommendation see pages 21-22, 24-27

xxxIf the yarn is close to the ring crown thermal damages can occur

Travellers with defined position of the yarn passage can help to avoid fibre damages

Application recommendations Application recommendations

2726 Spinning of compact yarns Spinning of slub yarns

Spinning of compact yarns

Processing of cotton on compact machines has now reached a big market share. Compact yarns have significantly reduced yarn hairiness. Therefore the fibre lubrication for the ring/traveller system is low.

On the other hand this yarn has a higher yarn strength, which allows higher spindle speeds.

Only by using best matching rings and travellers the compact yarn can be spun with highest spindle speeds and maximum traveller service life.

Rings:TITAN flange rings are recommended for the entire range of application.

Travellers:Low yarn clearance and an ultra-half round “udr” profile is used for almost all yarn counts.

Traveller finishes and treatments:SAPHIR for high performance.PYRIT for high performance and increased traveller service life.ZIRKON for high performance and maximum traveller service life.

Traveller recommendation

C1 EL udr traveller with a small yarn clearance

Conventional yarn

Compact yarn

Yarn count (Ne) 8 10 12 14 16 20 24 30 36 40 50 60 70 80 100 120 140

Carded and

combed cotton

Flange 2 M2 udr /dr

C1 SL udr

C1 EL udr

C1 SEL udr

C1 SKL udr

C1 UL udr

Spinning of slub yarns

Slub yarns (effect yarns, fancy yarns), become more and more important. A slub yarn allowsinnovative solutions for new fabric creations.

Slub yarns are yarns with defined mass variation in terms of length and thickness. Slub yarns are produced individually according the requirements of the customers.

For the traveller selection, the length and the thickness and furthermore, the frequency of the slubs are important.


Rings:TITAN or THERMO 800, Flange 1, for coarse counts Flange 2.

Travellers:Travellers with high-bow, for sufficient space for the slubs, a dr profile allows a smooth passing of the slubs. The traveller weight depends on the mass variation of the slubs, in general a higher weight compared to regular yarn is necessary. Control of the balloon by the traveller weight is important.

Traveller finishes and treatments:SAPHIR and STARLET for high performance.PYRIT for high performance and increased traveller service life.

Flange 1

Yarn count (Ne) Coarse counts / Slubs

Slub, Effect,

Fancy-Yarns

Flange 2C2 HW dr

C2 MM dr

C1 HW dr

EM1 / M1 dr

C1 MM udr

H2 dr / EH2 dr

Flange 1

Medim counts / Slubs Fine counts / Slubs

Due to the wide variety of slub or fancy yarns,

only a general recommendation is possible



2928 Spinning of soft core yarns Spinning of hard core yarns

Spinning of soft core yarns (Elastan)

Yarns with an Elastan (Lycra, Spandex) filament, which are wrapped around by staple fibres, mostly cotton. When spinning core yarn it must be avoided that the wrapping fibres get pushed back, in particular the yarn passage and the profile of the traveller have to be carefully selected.

The traveller speeds are limited, because operating with high speeds generates high temperatures on the ring-traveller contact area, which can lead to thermal damages of the Elestan core. To high a yarn tension can damage the core filament, therefore lighter weight travellers compared to regular yarns are recommended.



Travellers:Regular travellers for cotton with a dr or udr Profile. Traveller speed 25 - 28 m/sec.

Traveller finishes and treatments:SAPHIR and STARLET for high performance.PYRIT for high performance and increased traveller service life.

Yarn count (Ne) 8 10 12 14 16 20 24 30 36 40 50 60 70 80

Soft core yarn

(Elastan)

Flange 2

Flange 1

Spinning of hard core yarns (PES)

Yarns with a (Polyester) filament in the centre, twisted around by staple fibres, mostly Polyesteror Cotton.

Hard core yarns are used for sewing thread. Due to the smooth surface of the filament, a very delicate yarn for spinning, the wrapping fibres do adhere insufficiently and may be pushed back.


Yarn count (Ne) 8 10 12 14 16 20 24 30 36 40 50 60 70 80

Hard core yarn

(PES)

Flange 2

Flange 1


Travellers:High-bowed travellers with a fr profile or a dr profile. Traveller speed 20 - 25 m/sec.Higher traveller weights compared to normal spinning.

Traveller finishes and treatments:SAPHIR and STARLET for high performance.PYRIT or ZIRKON for high performance and increased traveller service life.

C2 HW dr

C2 MM dr

M2 dr

EM1 / M1 dr

EM1 / M1 udr / dr

C1 UL udr

H2 dr

H2 fr

M2 dr

C1 SM fr

EM 1 fr

EM 1 dr

H2 dr / C2 HW dr

C1 SH fr


3130 Lubrication of Ring/Traveller system Lubrication of ring/traveller systemYarn clearance

Yarn clearance

The yarn clearance must be adapted to the yarn count, yarn twist (volume) as well as to the fibres processed. This is achieved by selecting the optimal traveller type.

The yarn clearance does also influence the lubrication of the ring / traveller system.• Reduced yarn clearance > good lubrication• Large yarn clearance > reduced lubrication

Traveller with small yarn clearance• Low centre of gravity - for fine cotton yarns - for compact yarns• Optimum ring lubrication

Traveller with medium yarn clearance• Small to medium yarn clearance for fine to medium cotton yarns• Normal ring lubrication

Traveller with large yarn clearance• Large yarn clearance for medium to coarse cotton yarns, also suitable for blends and synthetics• Reduced ring lubrication

In short staple spinning, the ring/traveller system performsunder so called “dry lubrication”. No lubricants like oil are added actively. The necessary lubricants between ring and traveller are provided by the fibres. In case of cotton, fibre fragments and natural cotton wax build up the lubrication film. When man-made-fibres are spun, a spinning finish isadded by the fibre manufacturer.

Lubrication of ring / traveller system

3332 Yarn clearance Yarn clearance

Yarn clearance

The traveller is subject to tension forces from the thread balloon. This makes defining the contact area between ring and traveller very complex.

By combining the traveller’s arc radius with its wire profile, the desired large traveller contact area is achieved already during the starting phase of a newly inserted traveller.

Traveller position and balloon shape on the top of the taper during spinning/winding

Traveller position and balloon shape on the base of the taper during spinning/winding

Yarn clearance and its influence onthe lubrication of the ring/traveller system

The required yarn clearance in the traveller must be selected according to the yarn count and to the fibres processed. It is determined by the traveller shape and the inclination of the traveller.

Effects of the yarn clearance on the yarn quality and the running behaviour of the traveller

The inclination of the traveller is primarily influenced by the spinning geometry and the spinning tension. The stronger the inclination of the traveller, the more the yarn clearance is reduced and the better the ring lubrication.

The influences of traveller shape and inclination are shown in the following pictures:

Inclination

Yarn clearance Small, low

Yarn count Fine Coarse

Fibre Cotton Synthetics, blends

Influence on lubrication film Good traveller lubrication Reduced traveller lubrication

Influence on yarn quality Danger of «push-back» neps Excellent yarn quality guaranteed and melting points (on synthetics)

Large, high

Medium inclination Strong inclination

Lubrication of ring/traveller system Lubrication of ring/traveller system

Top of taper

Bottom of taper

3534 Yarn clearance Yarn clearance

Motions of the ring traveller

The traveller has, among other functions, the important task to level out the different balloon forces. The following parameters are decisive:

• Ring rail stroke build-up of cop (influence of tube length)• Ring rail stroke during one traverse (small-/large cop diameter) determines the traveller pulling angle (α)• Variations of speeds over cops build-up• Coefficient of friction ring/traveller (ring lubrication)• Changes in yarn tension due to winding on smaller and larger cop diameter (angel α)

The traveller changes its position during itswork on the spinning ring in addition to thecircular movement in 3 different directions:• Tilting motion K• Pitching motion N• Radial motion R

ConclusionThe traveller is the balancing element in the spinning process. The right adjustment respectively choice of traveller under consideration of all mentionedparameters is decisive for the performance and the yarn quality.

Examples of traveller positions

In theory

Contact area

In reality

Spinning on empty tube:

α large

Tight balloon

Spinning on full cop:

α small

Soft balloon

α

α

K

K

R

N

N

R

Lubrication of ring/traveller system Lubrication of ring/traveller system

3736 ORBIT and SU ring/ traveller system ORBIT and SU ring/traveller systemORBIT ring/traveller system

ORBIT ring/traveller system

The ORBIT ring/traveller system (patented world-wide) is designed for spinning at top speeds whilst producing best yarn quality.

The special features of the ORBIT system are:• Large contact area between traveller and ring reduces the specific pressure• Optimum heat dissipation traveller to ring

The ORBIT system offers the following advantages:• Increase in speed and production• High dynamic stability in traveller running• Reduction of yarn breakages• Improved and more consistent yarn quality• No thermal damage when processing synthetics

ApplicationFibres: • Cotton combed • Polyester/cotton blends • Polyester 100%

Yarn count • Ne 30 to Ne 60 recommendedrange: • Finer and coarser possible

Contact surface

Designed with an enlarged contact area between ringand traveller, the unique ORBIT / SU ring / traveller systemenables higher productivity especially when spinningheat sensitive raw materials.

ORBIT and SUring/ traveller system

3938 ORBIT ring/traveller system Traveller wear and tear

Traveller wear and tear

Travellers for ORBIT rings

Shape Designation Profile ISO number range Application

• Cotton• Polyester• Blends medium - coarse

• Cotton• Blends• Compact yarns Ne 36 and coarser

• Cotton• Blends fine yarn counts• Compact yarns Ne 30 and finer

SFB 2.8 PM:for all fibre types, large yarn clearance, therefore especially suitable for man-made fibres.

SFB 2.8 RL:small yarn clearance, especially suitable for cotton yarn, good ring lubrication. Possible to process fine yarn count blends (cotton/polyester) and for compact yarns.

The travellers for ORBIT rings are inserted with the well-established RAPID tool (see page 72).

SFB travellers are supplied in magazined packaging.

Finish:SFB travellers are available in SAPHIR, STARLET, PYRIT and ZIRKON finish.

12.5 - 125

18 - 80

12.5 - 71

dr

udr

dr

SFB 2.8 PM

SFB 2.8 RL

Visual assessment

Traveller weight OKOptimal wear distribution

Traveller weight is too heavyExcessive wear in area B

Traveller weight is lightExcessive wear in area A

Heavy traveller wear - possible remedies:If more than 10% of the travellers are worn out:• Reduce changing cycle of travellers• Reduce spindle speed• Check the rings• Possibly change traveller shape, wire cross section or traveller weight

B

A

B

A

B

A

B

A

ORBIT and SU ring/traveller system ORBIT and SU ring/traveller system

4140 SU ring/traveller system SU ring/traveller system

SU ring/traveller system

The SU ring/traveller system is suitable for the processing of synthetics (PAC, CV, PES) and their blends in the medium to coarse yarn count range (recommended up to Ne 36). In some cases the conical, lubricated rings can be replaced by the SU ring/traveller system.

The design features of the SU system are:• Large contact area between ring and traveller reduces the specific pressure.• Optimum heat dissipation traveller to ring

The SU ring/traveller system provides following advantages:• No lubrication required (as against conical rings; not suitable for wool and wool blends)• Better and more even yarn quality• Consistent yarn tension• No thermal fibre damages• Increased life cycle of travellers and rings• Higher spindle speeds• Lower yarn breakage rate• No staining of the yarn

Contact surface

Travellers for SU rings

Shape Designation Profile ISO number range Application

• Acrylics• Polyester• Blends

• Viscose• Viscose blends

• Acrylics• Fibres with strong softening agents

• Acrylics• Polyester• Blends

SU-BFor all synthetics and blends

SU-BFFor viscose fibres, higher speeds compared to SU-B and SU-BM

SU-BM• For all synthetics and blends• Enlarged yarn clearance, especially suitable for delicate fibres• The travellers for the SU-rings are inserted with the well proven RAPID tool SU (see page 74)

Finish• SU travellers are available in SAPHIR and STARLET finish• Traveller weights/yarn counts (see page 15)

31.5 - 400

28 - 90

50 - 280

35.5 - 280

drh

udr

r

drh

SU-B

SU-BF

SU-B

SU-BM


4342 Setting of the traveller cleaner Setting of the traveller cleaner

Setting of the traveller cleaner

Guiding value setting “b”:

b

Traveller No ISO b

< 63 56 – 112 > 100

1.7 mm1.9 mm2.1 mm

Tangential traveller cleaner

b

Traveller No ISO b

12.5 – 40 28 – 80 63 – 125

1.5 mm1.9 mm2.2 mm

Caution! Under no circumstances should the traveller touch the cleaner.

The traveller number used at the end of the ring running-in program, i.e. the one for normal operation, is decisive.

Mounting height of the tangential cleaner:4.5 mm below the ring crown.

Guiding value setting “b”:

4.5

mm


4544 Rings RingsDesignation of the ring parts

Designation of the ring parts, example for placing an order

Example for placing an order; requesting a quotationThe following specifications are required:

see page example

Ring type Bräcker 49-50 TITAN Flange with E 45 Flange 1; 3.2 mm Flange profile 45 Normal; N98 Inner diameter A 46 42 mm Fitting diameter B 49 mm Shoulder diameter (largest ø) C 51 mm Ring height D 46 18 mm Machine type Zinser 330

E A

B

C

D

E A

B / C

D

A Inner diameter

B Fitting diameter

C Shoulder diameter

D Ring height

E Flange width

Bräcker develops and produces a wide selection of ringsfor all requirements in ring spinning. Bräcker spinning ringsare available in all dimensions suitable for any ring spinningframe.The consistency of Bräcker ring quality ensures long service life at high spinning speeds.

Rings

4746 Finishes and treatments Ring profiles

Flange-, ORBIT- and SU-rings

Bräcker world standard for flange rings.The international standard for spinning rings ISO 96-1 specifies inner and seating diameter, ring height and flange size. The flange profile (shape) is not specified.

In order to make traveller selection (ring/traveller combination) more efficient, Bräcker has set its flange N98 profile as the standard.

TITAN rings

TITAN rings feature an extremely wear-resistant surface coating.• High performance application• For coarse to fine counts and high speed• Compact yarn• Long service life• Extremely high wear resistance• High temperature resistance prevents micro-welding and ring damage• The running track of the TITAN rings has already an ideal surface for the travellers• Short running-in procedure• The benchmark for spinning rings

THERMO 800 rings

The THERMO 800 rings are made of tempered steel and are available in flange 1 and 2 execution only.• For full count range at regular speeds• For coarse counts (Denim)• For core yarns (sewing thread)• Thermo-chemical treatment for universal application

Ring profilesFinishes and treatments

Flange ½

flange width 2.6 mm

Flange 1

flange width 3.2 mm

Flange 2

flange width 4 mm

ORBIT

SFB 2.8

with supporting ring

SU

with supporting area;

with supporting ring also available

Rings Rings

4948 Rings shapes Bräcker ring holder assembly system

Valuable only for flange rings in TITAN finish.Every ring spinning manufacturer has its own system for fixing the rings on the ring rails.The ring flange, which is the most important part, is standardized (ISO 96-1, see also page 45)

Bräcker ring / holder assembly system (two-part rings)Ring shapes

According to ring spinning machine(fixing methods)

Solid ringsFlange ½ (2.6 mm), Flange 1 (3.2 mm) and Flange 2 (4 mm)Ring finish TITAN and THERMO 800Ring inner diameter 36 mm, 38 mm, 40 mm, 42 mm, 45 mm, 48 mm, 51 mm, 54 mm(different or larger diameters on request)

Height 8 mm

for Rieter and Lakshmi

Height 10 mm

for all Chinese spinning machines

Height 11 mm

for Marzoli

Height 18 mm

for Zinser

Height 19 mm

for Toyoda, Howa and KTTM

ORBIT SU

Oblique ringsORBIT / TITAN ring inner diameter 36 mm, 38 mm, 40 mm, 42 mm, 45 mm

SU / TITAN ring inner diameter 42 mm, 45 mm, 48 mm, 51 mm, 55 mm

Can be adapted on all ring

spinning machines

Assembly with metal foot

for all Chinese spinning machines

Assembly with Alu-holder

for Zinser, Toyota, Howa and KTTM

Assembly with sheet

metal holder and traveller cleaner

for Zinser

Ring finish Flange ½ (2.6 mm) Flange 1 (3.2 mm) Flange 2 (4.0 mm)

TITAN

The Bräcker ring/holder system consists of the standardized upper ring part and the correspondingholder, forming the assembly group. With the holders individually designed for the requirement of the various ring spinning machines. This allows to standardize the upper ring part in order to offer an economic solution.

Ring assemblies (with standard TITAN rings)

Ring assembly, Flange

ø 36, 38, 40, 42 mm ø 36, 38, 40, 42, 45 mm ø 42, 45, 48 mm

Rings Rings

Per

form

ance

Yarn Count (Ne)

Per

form

ance

5150 Fixing methods Application matrix

Application matrix for Bräcker spinning ringsFixing methods

TITAN rings with assembly system (two-part rings)

Assembly Group

Zinser spinning machines

Assembly with Alu-holder

Circlip fixation

Zinser, Toyota, KTTM

Solid rings; TITAN and THERMO 800

Rieter and Lakshmi ring

spinning machines

Solid ring for Chinese machines Circlip fixation; Zinser, Toyota

and KTTM ring spinng machines

Cotton / none-compact

Per

form

ance

Yarn Count (Ne)

Per

form

ance

Ne 12

Ne 30Ne 60

TITANFlange 2

TITANFlange 1Flange 2

TITANORBIT

Flange 1

TITANFlange 1

Flange 1/2

THERMO 800Flange 1Flange 2

THERMO 800Flange 2

THERMO 800Flange 1

Ne 24 Ne 50

TITANFlange 1TITAN

Flange 1Flange 2

TITANORBIT

Flange 1

THERMO 800Flange 1Flange 2

THERMO 800Flange 2SU-Ring

THERMO 800Flange 1

Ne 14

TITANFlange 2SU-Ring

Polyester, Polyester / blends

For all Chinese ring spinning machines

Rings Rings

5352 Application matrix Requirements for optimum results

Per

form

ance

Yarn Count (Ne)P

erfo

rman

ce

Application matrix for Bräcker spinning rings

Cotton compact

Per

form

ance

Yarn Count (Ne)

Per

form

ance

Ne 12

Ne 30Ne 60

TITANFlange 2

TITANFlange 1

TITANFlange 1

TITANFlange 1

Flange 1/2

Ne 14

Viscose, Viscose / blends

TITANFlange 2SU-Ring

TITANFlange 1

Requirements for optimal results with Bräcker rings and travellers

The spinning geometry of the spinning machines should be adapted to the yarns produced. By modifying these parameters, the following values should be considered:

Important is the centering of the spinning rings, anti-ballooning rings and thread guides towardsthe spindle.

This guarantees (together with perfect ring raceway and correctly selected travellers) bestyarn quality and performance.

Thread guide• Distance top of the tube/ thread guide = 1.5 to 2 x ø tube (ring rail position at starting position)

Anti-ballooning ring• Anti-ballooning ø ring = ø ring + 2 mm• Distance ring rail/anti-ballooning ring (ring rail position in starting position) = 2/3 of the distance ring rail/thread guide

Spinning ring• Spinning ø ring: max. 1/5 of the tube length, see chart below• Horizontal, firm fixation of the rings in the ring rail• Correct setting of the traveller cleaner (see pages 17-19, 40-41)

ø Ring(mm) D Tube length (mm) L Medium ø tube (mm)

36 170 180 190 200

38 180 190 200 210

40 190 200 210 220

42 200 210 220 230

45 210 220 230 240

48 220 230 240 250

51 230 240 250 260

54 240 250 260 270

18 19 20 16 17

19 20 21 17 18

20 21 22 18 19

21 22 23 19 20

22 23 24 20 21

23 24 25 21 22

24 25 26 22 23

25 26 27 23 24

Ideal range

Unfavourable range

D

L

Recommended ring / tube ratio

Rings Rings

5554 Start-up proceeding for new rings Start-up proceeding for new rings

Start-up proceeding for new rings (ring running-in)

Ring fixing

The rings have to be fixed securely, horizontally and concentric with the spindle. It is not necessary to clean Bräcker rings, the special conservation material helps the start-up of the rings. Should the rings nevertheless be cleaned, use only a dry cloth (do not use any solvents).

Running-in procedure for THERMO 800 rigsConventional rings must go through a running-in program. By doing this, the ring raceway is smoothend and passivated (oxidation) through the applied travellers. At the same time the necessary lubrication film coming from wax, softening agents and fibre fragments is built up. Depending on the firbre spun, yarn counts and final speed, the spindle speed must be reduced for the first 10 to 20 traveller changes. It is essential that the ring running-in is carried out carefully, as this will improve the general running conditions and in addition it will extend the ring life.

Start-up proceeding for TITAN ringsUnder normal condition the TITAN coating can notbe affected by the traveller. However, in the firstphase, the traveller has to build-up a lubrication film on the ring and this depends on the processed fibre material and yarn count. For regular fibres, the start-up proceeding is carried out without reduction of the RPM, only the first traveller change intervals are shortened. For compact yarns and very fine yarns (from Ne 80) a special start-up program must be applied.

Ring load

In order to prevent any damage on TITAN rings, one should not exceed the ring load asindicated in the diagram/table below. Bräcker takes no liability for damaged rings if therecommended loads have been exceeded.

Selecting travellersThe same travellers as for the regular spinning operation can be used.

Ring loadAvoid too heavy loads on the traveller raceway of the rings.

Traveller wearAvoid heavy traveller wear at start-up and regular running in order to prevent premature ring wear.

Running-in program, start-up instructionInstructions corresponding to each Bräcker ring type are delivered with each shipment. Upon request, a specially adapted program can be provided too. Please contact your local agent.

For establishing a running-in program we need the following specifications:• Ring diameter• Ring type, flange size• Fibre type, yarn count, twist• Final speed (rpm)• Presently used traveller (type and weight)• Present traveller life

Load

in m

N

6000

5000

4000

3000

2000

Ring inner diameter in mm

Cotton

Pes / Blends

5000

6000

4850

5800

4650

5600

4300

5200

4000

4800

3600

4400

3250

4000

2900

3600

54 51 48 45 42 40 38 36

Formulas

Ring load

L = m · v2

r

L = ring load in mNm = traveller weight in mgv = traveller speed in m/sr = ring radius in mm (ring-ø/2)

Traveller wear see page 54

Start-up instruction (ring running-in) see page 52

Maximum spindle speed

RPMmax = L · d 60 · 1000

m · 2 d · 3.14

L = ring load in mNm = traveller weight in mgd = ring ø in mm

.

Maximum ring load in mN

Rings Rings

5756 Start-up proceeding for new rings Start-up proceeding for new rings

Traveller wear, insufficient lubrication

In order to prevent premature ring wear check the traveller wear rate and traveller wear pattern at running-in and during normal operation. With these two parameters one can judge if the ring load is within the limits and ring lubrication is sufficient.

Ring life time

The ring life time depends on various parameters. The following table explains the correlation.Attention: An accumulation of causes is possible.

Liability

Bräcker takes no liability for

damaged rings if the described

instructions are not followed.

This for the running-in as well

as for regular operation.

Normal traveller wear

Working condition ok.

Excessive traveller wear

If more than 20% of

checked travellers show

heavy wear, reduce spindle

speed until normal traveller

wear is achieved.

Abnormal traveller wear

If abnormal wear is noticed, reduce

spindle speed. Insufficient ring

lubrication causes a wear pattern

as shown in the picture above.

low

Parameter

Yarn count range Ne 6 - 16 high Ne 40 - 80 Ne 60 - 140

Fibre

Yarn

Traveller

Performance

Spinninggeometry

Machines

Chlorine

Ring stress Remarks

Cotton

Man made

Softening agents

Yarn count

Shape

Life time

Traveller speed

Ring diameter

Centring

Vibration

Fibres

Air condition and spinning environment

Dry

Dull

Aggressive

Coarse

High-bowed

High traveller wear

High

Smaller

Poor

Strong

Danger

Danger

High waxproportion

Bright

Lubricating

Fine

Low-bowed

Low traveller wear

Normal

Larger

Good

None, low

High wax proportion increases thelubrication

Dull fibres include abrasive particles(e.g. Titan oxide)

Influence on lubrication

Higher load with heavier traveller

Better lubrication with low-bowed travellers

Heavy worn-out travellers damagethe traveller raceway of the rings(see page 37, 54)

Higher load at high speeds (see page 68)

The ring periphery of a small ring isshorter. This leads to higher stresson the running track of the ring

Badly centred rings, anti-ballooningrings and thread guides produceirregular loads

Inconsistent loads lead to prematurewear and tear

Fibres containing chlorine maydamage also TITAN rings

Chlorine contaminated water must be avoided

TITAN rings are not very sensitive to wear and tear and have generally a very long life time. A ring replacement is advisable, when the desired yarn quality can not be achieved any more or yarn breaks due to damaged rings are increasing.

Rings Rings

Wear and tear on rings

TITAN rings

The high wear resistance and its consistency from ring to ring guarantee a ring life of up to 10 years. Over the full ring life time the TITAN rings have the same surface characteristic.

TITAN - same surface condition over entire ring life

Therefore we guarantee a positive influence on performance and yarn quality when using TITAN rings.

TITAN with ideal surface conditions over

the entire life time

Conventional steel rings:

The surface of a conventional steel spinning ring is not protected against abrasion. Permanent wear and tear is leading to an increasing roughness of the ring surface at the traveller race way.

Steel ring - surface condition changes due to wear

This influences the spinning tension and can have a negative impact on yarn hairiness, variation of yarn hairiness and yarn breaks.

Acceptable surface Critical wear on traveller raceway Worn out steel ring

5958 Wear and tear on rings Wear and tear on ringsRings Rings

Technical spinning information

Yarn breaks

GeneralThe yarn break rate is besides the yarn quality the limitation for the spindle speed. By reducing yarn breaks, the spinning costs become lower and the productivity increases.

By selecting the right ring and traveller, theperformance can be substantially influenced.

Calculation of yarn break rateYarn breaks / 1000 spindles / hour:

Yarn breaks . 1000 . 60

No. of spindles . observation time (min.)

Influence of the speed on the yarn breaksAt higher speeds more yarn is produced. As the yarn breaks are mostly counted per time unit, the latter has to be considered.

At higher speeds (with identical spinning geometry)the spinning tension is bound to be higher.

The yarn strength however does not change; therefore the probability of yarn breaks does increase.

Therefore on state-of-the-art ring spinning machines the spindle rotation is adjusted accordingly (reduction on the base and top of the cop in order to avoid spinning tension peaks).

Distribution of yarn breaks whilebuilding up of the cop

Yarn breaks

Cop

bui

ld-u

p

6160 Performance and spinning quality Performance and spinning qualityTechnical spinning information

The ring and traveller system has a significant influence on the performance of a ring spinning machine and on the yarn quality. For an efficient production of ring yarn other parameters e.g. spinning geometry, climatic conditions, adjustments of components and machine play an important role.

Performance and spinning quality

Causes of yarn breaks during spinning process

Yarn breaks can have different causes. A perfect ring condition and the selection of the right travellers are of utmost importance.

Breaks during spinning process

Causes of yarn breaks

Spinning tension too high resp. too low

High variation of spinning tension from spindle to spindle

Fibre accumulation on travellers (fibre loading)

Poor condition of ring (worn out)

Short traveller life, traveller is flying off

Bent travellers during the inserting operation(ISO 25 and finer)

Adjust traveller weight, strive for a well-balancedballoon, avoid “double” ballooning

Unsuitable traveller type, select another travellertype, correct centering of rings, anti-balloon ringsand yarn guide eyelet

Adjust traveller clearer (see page 29) select a travellerwith higher bow

Replace rings

Unsuitable traveller type, use traveller with a lowerbow, in order to improve the lubrication. Activatetraveller running in program after traveller change

Use well-adjusted RAPID inserting tool, handlewith care when manually inserting

Corrective action

Drafting components

Worn out top roller cover (groove formation)

Surface roughness insufficient (glassy surface)

Top roller cover too hard

Fibre wrapping tendency of the top roller covers

Worn out aprons (groove formation, cracks on the surface)

Aprons with insufficient roughness (glassy surface)

Cradle spacer

Reduce grinding cycle of the top roller covers

Reduce grinding cycle of the top roller covers

Select a top roller with lower shore A hardness

Surface treatment through “berkolizing”; adjust climatic conditions. Redressing and cleaning of grinding stone, in order to control the roughness of the top rollers

Replace aprons

Replace aprons

Select the cradle spacer according to the yarn count

Ring and Traveller

Breaks during spinning process


Ring, anti-balloon ring and yarn guide eyelet must be adjusted concentric to the spindle

Worn out rings, anti-balloon ring and yarn guide eyelet

Spindles and tubes

Inaccurate adjustment of these elements createsan unstable traveller running, higher spinning tensionand shorter service life of ring and travellers.For best results Bräcker is recommending a ringto spindle concentricity of +/- 0.2 mm

Replacement

Spindles and tubes vibrations influence directly the traveller running and service live of ring and travellers; tension peaks and yarn breaks are the consequences

Corrective action

Other factors

Fibre properties like staple length, short fibre content, trash and dust content

Mass irregularity (CVm) thin-, thick places and neps, yarn strength

Recommended climatic conditions for ring spinning:Cotton:Synthetic fibres:

Compromise in fibre selection can lead to higheryarn breaks. High trash and seed coat content can lead to traveller loading

Adjust fibre preparation, higher CVm and imperfectionsincrease the probability of a yarn break

28°- 32° C, 38% - 48% RH23°- 28° C, 45% - 54% RHWater content: 9 g/kg - 12 g/kg

Water used in the air-conditioning should be as free as possible of mineral salt and chlorine. These elements can lead to corrosion.

Mechanical components and settings

6362 Technical spinning information Technical spinning informationPerformance and spinning quality Performance and spinning quality

Causes of yarn breaks during doffing

Start-up yarn breaks may have various causes. It is of utmost importance to make first a proper analysis when and where the start-up breaks occur.

When do start-up breaks occur?


Are yarns unthreaded from travellers noticed?Check if yarn is properly stretched, curled yarn indicates yarn unthreaded from travellerDown-winding: 1½ turns recommended

Check the spindle stop proceeding

Corrective action

Start phase

Yarn breaks due to jammed traveller

High curling tendency of the yarn

Yarn is wrapped around snail wire?Indication that yarn unthreaded of the traveller orunstable balloon building

Try different traveller shape, normally higher bow

Delay start of drafting system

Balloon build-up is not stable, speed-up the spindle(steeper speed ramp). Heavy-up traveller weight. Try different traveller shape, normally higher or wider bow.

After under-winding

Are broken ends noticed?Are under-winding layers correct and firm?

Adjust under-winding motion to get firm yarn layer

After doffing, before restart

Does yarn stay threaded in traveller? Reduce pull-up stroke.The higher the stroke the higher the possibility of unthreading due to the flat angle of yarn to the traveller

Pull-up phase (ring rail)

Hairiness

Yarn hairiness

We speak of yarn hairiness when the body of the yarn has an exceeding number of longhair protruding out of it.

Hairiness is considered as a disturbance in the following operations:

• Fibre fluff in all stage of production• Winding• Sizing machine (lateral hooking)• Warping, beam warping (dust)• Weaving (weft bars)• Dying (uneven dye absorption)

6564 Technical spinning information HairinessPerformance and spinning quality Performance and spinning quality

Causes of yarn hairiness

Ring condition

• Rough and uneven surface disturbs smooth running of the traveller

• Replace rings

Corrective action

Uneven yarn tension

• Poor ring centering• Poorly centered thread guides, antiballoon-rings or damaged parts• Crooked tubes• Spindle vibrations

• Recentering of all elements• Replacement of all damaged parts

• Replace tubes• Replace spindles

Electrostatic

• The fibres get electrostatically loaded • Increase air humidity

Traveller shape

• Insufficient yarn clearance • Use a traveller type with a larger yarn clearance

Traveller wear

• Worn out yarn passage of the traveller (Viscose)• Worn out travellers (Ring-Traveller contact area)

• Reduce traveller running time• Replace travellers

Traveller profile

• The wire profile can influence the hairiness and yarn tension

• The f-profile can reduce the yarn hairiness, (adjust traveller weight)

Traveller weight too light

• Poor twist propagation to the spin triangle• Heavy friction of the anti-balloon ring resp. impact on the separators

• Increase traveller weight or choose another type

Traveller wear too heavy

• High friction of the yarn leading to hairiness (Neps)• Too heavy traveller weight leading to traveller wear

• Reduce traveller weight

Neps

When neps are mentioned in connection with rings and travellers, it means production neps, or push-back neps. They do occur merely (and they are measurable) on yarns Ne 40 and finer.

Formation of neps

Production neps do mainly occur in the upper half of the cop. It is the matter of push-back, retained fibres and they do arise on tight gliding points and edges as well as at excessive spinning tensions.

Cause

Yarn clearance too small, yarn passage intersects with the wear and tear spot

Unsuitable wire profile

Spinning tension too high

Notched thread guide

Select a traveller with a higher bow

Change from f to udr, resp. from udr to dr

Select a lighter traveller

Replace

Remedy

Production neps Yarn clearance

When yarn passage and

wear an tear area separated:

No risk for neps.

When yarn passage intersects

with wear and tear area:

Formation of neps possible.

Yarn clearance

Wear and tear area

6766 Hairiness NepsPerformance and spinning quality Performance and spinning quality

Technical spinning information

tex

100,0

84,0

72,0

64,0

60,0

56,0

50,0

46,0

42,0

36,0

34,0

32,0

30,0

25,0

23,0

21,0

20,0

17,0

14,0

12,5

12,0

10,0

8,3

7,4

6,6

5,8

5,5

5,0

4,0

3,3

900

750

643

563

529

500

450

409

375

321

300

281

265

225

205

188

180

150

129

113

108

90

75

67

60

52

50

45

36

30

10,0

12,0

14,0

16,0

17,0

18,0

20,0

22,0

24,0

28,0

30,0

32,0

34,0

40,0

44,0

48,0

50,0

60,0

70,0

80,0

85,0

100,0

120,0

135,0

150,0

170,0

180,0

200,0

250,0

300,0

6,0

7,0

8,3

9,5

10,0

10,6

12,0

13,0

14,0

16,5

18,0

19,0

20,0

24,0

26,0

28,0

30,0

36,0

40,0

48,0

50,0

60,0

70,0

80,0

90,0

100,0

105,0

120,0

150,0

180,0

den Nm NeC

Numbering systems for yarns and twists

Yarn count comparison chart (rounded figures) Conversion formulasLäufer-Nr. Bräcker R + F

Tex

Decitex

Denier

Metric no

Engl.

cotton no

tex

dtex

den

Nm

NeC

-

0.1 dtex

10 tex

-

1.111 den

9 tex

-

1000

tex

590

tex

1.693 NeC

0.590 Nm

Abbre-viation

tex dtex den Nm NeC

10000

dtex

5900

dtex

9000

den

5315

den

1000

Nm

10000

Nm

9000

Nm

590

NeC

5900

NeC

5315

NeC

Desired

Given

0.111 den

0,9 tex

-

-

Twist Twist multiplier

with Ne T/” = αe · Ne with Ne αe =

with Nm T/m = αm · Nm with Nm αm =

with tex T/m = with tex αtex = T/m · tex

Conversion formula Twist

T/” = T/m · 0.0254 T/m = T/” · 39.4αm = αe · 30.3 αe = αm · 0.033

tex =

den =

Nm =

NeC =

T”

Ne

T/m

Nm

αtex

tex

g1000 m

g9000 m

m1 g

840 ydspound

6968 Numbering systems for yarns and twists Numbering systems for yarns and twistsPerformance and spinning quality Performance and spinning quality

Traveller speeds/performance calculations

Ring ømm Traveller speed m/sec

60 28 29 31 33 34 36 37 39 40 42 44 45

57 25 27 28 30 31 32 34 35 37 38 40 41

54 25 26 28 29 31 32 34 35 36 38 39 41 42 43 45

51 24 25 26 28 29 30 32 33 34 36 37 38 40 41 42

48 22 24 25 26 27 29 30 31 32 34 35 36 37 39 40 41 42 44

45 21 22 23 24 26 27 28 29 30 31 33 34 35 36 37 39 40 41 42 43 44

42 26 27 28 29 30 32 33 34 35 36 37 38 39 40 41 43 44 45

40 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 41 42 43

38 27 28 29 30 31 32 33 34 35 36 37 38 39 40 40 41 42 43 45 46 47 48 49 50

36 28 29 30 31 32 33 34 35 36 37 38 39 40 41 41 42 43 44 45 46 47

Formula: = m / s

ring diameter . π . n (rpm)

1000 . 60

Traveller speeds in m/s (rounded figures), ring diameter 36 - 70 mm

L = Delivery in m/min.Ppr = Production in practicen = Spindle speed in min-1T/m = Twists per mg/h = Gram/hour (spindle)λ = Efficiency

Performance calculations

Delivery:

L = = m/min

Production:

Ppr = · λ = g/h

or

Ppr = · λ = g/h

n

T/m

L · tex · 60

1000

n · tex · 60

T/m x 1000

9 00

09

500

10 0

00

10 5

0011

000

11 5

00

12 0

0012

500

13 0

00

13 5

0014

000

14 5

00

15 0

0015

500

16 0

00

16 5

0017

000

17 5

00

18 0

0018

500

19 0

00

19 5

0020

000

20 5

00

21 0

0021

500

22 0

00

22 5

0023

000

23 5

00

24 0

0024

500

25 0

00

Spindle speed n/min (rpm)

7170 Traveller speeds/performance calculationsPerformance and spinning quality

7372 Tools ToolsROLSPRINT

ROLSPRINT - Fluff removerTechnically advanced tool with gears of hardened steel and special easy running ball bearings.Exchangeable tip.Standard spindle lengths:250 mm and 400 mm

SECUTEX - Cutting tool• Safety cutter with blade protection• Exchangeable steel blade

CUTEX - Cutting tool• Tuft cutter with brass blade (exchangeable)• Standard lengths: 50 mm and 100 mm

CLIX - Inserting and removing• For inserting (loose) and removing the following travellers:• C-shaped; ORBIT; SU

OUTY - Removing• For removing C-shaped travellers• Removed travellers are collected in the handle

The Bräcker product range includes various types of inserting, cleaning and cutting tools for the spinning industry. Bräcker RAPID inserting tools allow spinning mills to change travellersvery quickly and efficiently with reduced labour involvement. Bräcker cleaning tools ROLSPRINT are very efficient fluff removers for the cleaning of textile machines. The Bräckercutting tools SECUTEX and CUTEX are suitable for use in various spinning mill departments.

Tools

7574 Inserting tools Inserting tools

Benefits when using Bräcker RAPID for inserting travellers

With this QR Code you can download films and technical documentation concerning the RAPID to your smartphone or Tablet PC.

Bräcker RAPID for C-shaped, ORBIT and SU travellers

Characteristics• Inserting tool for magazined travellers• Simple setting with traveller as a gauge• Possible threading of the yarn in the traveller when inserting• Specially suited to small gauges or when ring data system is installed• The fastest way to insert travellers

ApplicationThe Bräcker RAPID provides following advantages:• Tool for inserting of magazined, C-shaped, ORBIT and SU travellers• Suitable for smallest ring diameters and minimal spindle gauges• Easy access also with installed traveller monitoring systems

Inserting tools for magazined travellers

Adantages for the Spinning MillsThe Bräcker RAPID provides following advantages:• Allows spinning mills to change travellers very quickly and efficiently• Fast and easy inserting of travellers• Simple setting with traveller as a gauge• Reduced labour costs• Less traveller losses• Combined inserting and threading possible• Higher productivity• Easy to use

RAPID AP RAPID STRAP

Manpower

Money

Production

Tools Tools

7776 Inserting tools Inserting tools

Bräcker BOY for C-shaped travellers

The Bräcker BOY is preferred for very heavy and / or very light weight travellers.

Profile 2)

Yarn count range Ne 6 - 16 Bräcker

L1 all all 679.401/402* .01

M1, EM1 all all 679.408 .03

C1 UL all all 679.419/420* .01

C1 SL all all 679.433/434* .01

C1 SEL all all 679.431/432* .09

C1 UM all all 679.424/425* .07

C1 LM all all 679.405 .07

12/0 - 2 18 - 71 679.427 .01

1 - 12 63 - 200 679.428 .03

EL1, C1 EL all all 679.441/442* .05

C1 SKL all all 679.435/436* .13

M2, EM2 all all 679.602/603* .51

H2, EH2 all all 679.617 .53

C2 UM all all 679.611 .55

4/0 - 6 40 - 100 679.620 .51

7 - 12 112 - 200 679.623 .53

C2 HW 6 - 26 100 - 200 679.646 .53

6/0 - 6 31.5 - 100 679.637 .73

7 - 20 112 - 355 679.636 .75

EM1 all all 679.409 .03

C1 SM all all 681.736 .55

C1 SH, H2 all all 681.923/730 .53

SU-BM, -BF all all 679.851 679.257

SU-B all 355 - 400 679.850 679.254

SU-B all 31.5 - 315 679.851 679.257

SFB 2.8 PM, RL all all 679.862/863* 679.256

Traveller shape

RAPID inserting tools - range of application

No. Range 1) Storing BarTool No.

ISO RAPID 400 Profile679.252.xx

C-shape

f, dr, udr

* Fine version: for travellers 8/0 (ISO 25) and lighter

1) For heavy travellers (above No.10-14 (ISO160 -250) use Bräcker Boy). Availability in AP/Strap according to our Delivery Program2) For r profile with C-shaped travellers use Bräcker Boy

AP

STRAP

C-shape

fr

all

all

all

C1 MM

C2 MM

C2

Type

C8 1 (3.2mm) From outside to inside

C9 2 (4.0mm)

C71 1 (3.2mm) From inside to outside

C72 2 (4.0mm) (for ring Ø ≥ 42mm)

Inserting of travellersFlange

Ring-Type

Yarn count range Ne 6 - 16 Bräcker

C1 HW dr 160 – 280 10 – 16 H2 / EH2

C1 MM udr 160 – 200 10 – 12 M1 / EM1

EM1 dr 160 – 315 10 – 18 C8 / C71

L1 f 7.1 – 16 26/0 – 14/0 L1 f

C1 EL udr 5.6 – 16 29/0 – 14/0 EL1

C2 MM 160 – 315 10 – 18

C2 HW 160 – 425 10 – 26

H2 f 160 – 250 10 – 14 H2 / EH2 C9 / C72

H2 dr

H2 fr 160 – 200 10 – 12

EH2 dr 160 – 560 10 – 36

Traveller-Type Range of travellers Boy-TypeStoring Bar /Profile No.

ISO

Flange 2

Flange 1

Traveller types not listed here should be inserted with Bräcker RAPID inserting tool.

Please see page 72-74

Recommended mainly for heavy travellers

(> No. 10, ISO 160)

Exception:

Light travellers L1 f and C1 EL udr.

Range of application

Tools Tools

7978 Magazining system

Bräcker AP (automatic packing)• Magazining system for C-shaped travellers• Flexible system for easy handling• Traveller designation (type and No) on AP rod (to avoid mix-ups)

AP rod to use with Bräcker RAPID and Bräcker BOY

Magazining system

Bräcker STRAP• The traveller is taken up on a profile STRAP, up to 10’000 per spool• STRAP system for: - ORBIT travellers - SU travellers - C-shaped travellers with fr-Profile

Profile STRAP to use with Bräcker RAPID only

Tools

8180 BERKOL® cots and aprons BERKOL® cots and apronsCots

The raw material

Compounds in the hardness range of approx. 65 to 82 shore A are used as coating raw materials. The composition of the raw material determines the characteristics of the cover such as:• Hardness• Elasticity• Grip• Abrasion resistance• Notch-tensile strength• Swelling resistance• Color

These characteristics should fulfil the following demands made on a top roller cover:• Good fibre guiding• No lap formation• Long working life• Good ageing resistance• Minimal film formation

BERKOL® cots

Berkol cots are technology components, which have a direct influence on yarn quality and the overall performance of a spinning mill. By choosing BERKOL® cots, one minimizes lap formation and yarn breaks while improving yarn quality. Productivity is optimised and production costs are reduced in an efficient manner. Bräcker offers a complete and broad range of quality BERKOL® aprons, with the right solution for any requirement. Their characteristics are: consistent running properties, excellent crack and abrasion resistance, exact dimensional stability, produced in several qualities and in various sizes.

BERKOL® cots and aprons

8382 Cots Cots

Selection of the top roller cover

The demands made on top roller covers have risenenormously in the last few years. The continuallyincreasing quality requirements and the higher processing speeds mean that great attention must be paid to the right choice of covers with regard to lap formation, working life, swelling, ageing as well as static charge.

excellent very good good satisfactory

Type of machine

Drawing frame

Combing machine Detaching roller

Delivery roller

Drafting system

Roving frame / speed frame / finisher

Ring spinning machine

Rotor spinning machine

Texturizing machine

Carded cotton

HA 65 SHA 80 OEHA 74 T

HA 70 THA 74 THA 80 OE

HA 65 AHA 67 THA 70 THA 74 THA 80 OE

HA 80 OEHA 74 T

Combed cotton

HA 65 SHA 80 OEHA 74 T

HA 65 S

HA 80 OE

HA 65 SHA 80 OE

HA 70 THA 74 THA 80 OE

HA 65 AHA 67 THA 70 THA 74 THA 80 OE

HA 80 OEHA 74 T

Blended yarns /synth. fibres

HA 80 OEHA 74 T

HA 80 OEHA 74 T

HA 70 THA 74 THA 80 OEHA 65 AHA 67 T

HA 80 OEHA 74 T

Wool

HA 80 OE

HA 80 OE

HA 80 OE

Synth. fibre long staple

HA 80 OE

HA 80 OE

HA 80 OE

Technical fibres

HA 80 OE

HA 80 OEHA 74 T

HA 80 OEHA 74 THA 70 T

Filaments

HA 75 D

Fibre quality

BERKOL® - rubber qualities / product selector

Material Colour Hardnessshore A

Resistance to Physical properties

HA 65 S

HA 67 T

HA 65 A

HA 70 T

HA 74 T

HA 80 OE

HA 75 D

brown

orange

light red

dark blue

dark green

yellow

black

67

67

68

70

74

80

78 not tested

Finishing agent grease, oil

Ageing,tempera-ture

Elasticity Lapformation

Abrasionresistance

Mechanical loadcapacitiy

Permanentdeformation

Product qualities in the BERKOL® top roller covers

The quality of the rubber covers to be selected should not be determined only in the light of the above mentioned characteristics, but also depends on the machine type, the climatic conditions and the yarn type and quality. This is why it is so important to take the advice of the cover manufacturer.

Full certainty in the choice of the optimal cover quality for your special requirements can only be gained through practical spinning tests in your plant.

BERKOL® cots and aprons BERKOL® cots and aprons

8584 Cots

New methods for the assembly of the rubber tube and the arbor had to be sought because of the increasing strain on the top rollers due to higher speeds, pressing-down forces and temperature.

The solution is BERKOL® alupress. The alupress cover consists of a precise aluminum tube, which the rubber is extruded and than vulcanised onto.

Technical advantages• The rubber coating is vulcanised stress free, eliminating the danger of ozone cracks.• The connection between the tube and the rubber guarantees perfect adhesion even under great pressure and at high temperatures.• The alupress can be pressed onto the top roller easily and fast.• Secure adhesion of the alu tube on the top roller.

Economic advantages• No tiresome sticking, it is simply pressed on - saving time and cost.• No waiting time, the cover can be ground immediately after pressing.• No cleaning required when replacing the cover.

The alupress covers can be pressed with manual, pneumatic or hydraulic presses onto the arbors. The BERKOL® presses guarantee exact guiding and positioning of the cover.

BERKOL® cots and aprons

86 Aprons

The BERKOL® top performing aprons are capable of processing 100% cotton as well as blends. As “bottom aprons” they are available in both long and short execution as well as for regular or compact spinning.

With the I-HX8/U-HP and I-HX8/C-HP aprons, we are able to increase the apron’s lifetime by up to 35%, compared to the well known I-HX8/U and I-HX8/C aprons. Another benefit for our customers is the fact, that improvements in yarn quality of up to 10% are frequently achieved.

BERKOL® aprons

The reasons for these improvements are:• Improved resistance against wear and tear due to minimal depression. This has a direct influence on the longevity and the quality consistency of these aprons.• Improved resistance against surface deformation. The quick recovery leads to optimal gripping and better control of the fibres.• Improved flex and ozone resistance leading to less cracking on the apron surface.• Improved tensile strength and tear resistance, reducing the risk of “snapping”.

Colour

Inner layer olive green / Outer layer grey

Inner layer dark green / Outer layer grey

Inner layer olive green / Outer layer light green

Inner layer dark green / Outer layer light green

Inner layer dark green / Outer layer dark blue

Expected lifetime

23-25 months

12-14 months22-24 months

19-21 months

10-12 months18-20 months

Finish

Antistatic

Antistatic

Antistatic

Antistatic

Antistatic

Recommended applications

Universal high performing apronsFor spinning 100% cotton as well as blends, for regular and for compact spinning

Universal high performing aprons For spinning 100% cotton as well as blends, for regular and for compact spinning

Universal standard apronsFor processing 100% cotton counts, regular and compact spinning

Universal standard apronsFor processing 100% cotton counts, regular and compact spinning

apronsFor processing synthetics and synthetic blends

Aprons

I-HX8/U-HP Top aprons

I-HX8/C-HPShort bottom aprons Long bottom aprons

I-HX8/U Top aprons

I-HX8/C Short bottom aprons Long bottom aprons

HX-3/S Bottom aprons

87ApronsBERKOL® cots and aprons BERKOL® cots and aprons

89BERKOL® maintenance machinesPresses

Proper fitting of alupress covers onto top rollers is one of the preconditions for producing high yarn quality.

The very high precision and safety of BERKOL® presses guarantee faultless, efficient operation. All our presses correspond to CE standard regulations.

Electro-hydraulic press APH50-H500EVElectro-hydraulic press for fitting and removing long Alupress covers used on preparatory machines and combers.

Range of application:Tool sets available for all commonly used dimensions of various machinery manufacturers supplied from stock. Special tools as per sample or drawing can be supplied on short delivery times.

Pneumatic press PP125-H100Pneumatic press for fitting and removing of short alupress covers on ring, roving, air jet spinning and OE delivery top rollers.

BERKOL® presses

Press range Up to 490 mmCore diameter Up to 35 mmCover diameter Up to 80 mmPress pressure Max. 29’000 NOperating pressure 80 – 100 bar

Press range 20 – 45 mmCore diameter 19 – 30 mmCover diameter Up to 60 mm

Press pressure At 6 bar: 6’500 N

At 8 bar: 8’600 NOperating pressure 6 – 8 bar

88 BERKOL® maintenance machines

Spinning mills benefit from BERKOL® total solution through perfectly coordinated product lines covering the entire spectrum of service and maintenance. BERKOL® grinding and Berkolizing machines and systems, presses, lubricating units and testing instruments for textile mill applications are appreciated throughout the world.

BERKOL® maintenance machines

9190 Grinding technology Grinding technology

The quality of the cots can only be ensuredfor its entire life if it is maintained properly.Regular grinding is part of this, optimal surfaceroughness and if necessary surface treatment of the freshly ground covers.

The result of optimal care:• Perfectly smooth running• Minimum lap formation• Lower thread break rate

The grinding interval is determined by• Cot shore hardness• Machine type (standard, compact, air)• Fiber type

Grinding technology

• The deterioration of yarn quality (CV%, IPI)• The increase in the thread break rate• The wear and tear of the cover (rut formation)• Film formation with resulting lap formation

Besides the cover quality, the grinding intervals are determined mainly by the application and the quality demands of the customer.

Years of experience and in-depth talks with customers have shown that each spinning mill must develop and define their own optimal values.

The information in the following table is therefore to be considered only as a guideline.

Application

Ring spinning machine

delivery top roller

The grinding intervals for

the feed top rollers can

be doubled

Roving frame delivery

top rollers

Drawing frame

Combing: detaching roller

drafting system

delivery top rollers

Open end spinning

machine delivery roller

Up to 70 shore A

70 – 75 shore A

76 shore A and up

Up to 70 shore A

70 – 75 shore A

76 shore A and up

Up to 70 shore A

70 – 75 shore A

76 shore A and up

Up to 70 shore A

70 – 75 shore A

76 shore A and up

Up to 70 shore A

70 – 75 shore A

76 shore A and up

67 shore A

67 shore A

80 – 82 shore A

80 shore A

Fine

Medium

Coarse

1250 – 1750

1500 – 2000

2000 – 2500

1000 – 1500

1250 – 1750

1750 – 2250

Not recommended

1000 – 1500

1250 – 1750

2500 – 3000

3000 – 3500

3500 – 4000

500 – 750

500 – 750

550 – 750

1500

1500

1500 (check)

1500

Cover type Yarn count range Grinding interval h

Covers from 70 shore A and up are recommended for the delivery top roller of compact spinning

machines. For softer covers, 20 - 30 % shorter grinding intervals must be adhered to.

The grinding depth depends on the wear and tear of the cover, we recommend 0.2 - 0.3 mm in diameter.

The optimal surface roughness depends on the cover material, the application and the climate. It has in particular an influence on the lap formation tendency of the cover. Good results were obtained with an average roughness (Ra) between 0.8 and 1.0 μm.

In order to obtain a defined surface roughness, the following factors are decisive:• Grinding machine• Type of grinding disc• Trimming of grinding disc• Settings of grinding machine

Most common grinding mistakeCommon view that the less that is removed from the cot when grinding, the longer the service life of the cot. Seems logical as less material is removed.

Consequences of insufficient removal of material are as follows:• No fresh rubber material on the “grinded” surface• Variation in surface roughness• Uneven cot surface• Cot surface not flat

Conclusion:Despite of yarn quality problems, more frequent regrinding is necessary, hence life time is shortend!

For grinding the top rollers, BERKOL® offers universal manual grinding machines or fully automatic grinding systems of modular design with integrated surface treatment.

μm (micrometer)

50 2000 N 12

25 1000 N 11

12.5 500 N 10

6.3 250 N 9

3.2 125 N 8

1.6 63 N 7

0.8 32 N 6

0.4 16 N 5

0.2 8 N 4

0.1 4 N 3

0.05 2 N 2

0.025 1 N 1

Roughness value Ra Roughness class

μin (microinch)

lap rate in %

100

50

0

fine roughmedium

surface structure

Polyester/83 ShA

BERKOL® maintenance machinesBERKOL® maintenance machines

9392 Grinding machine tpe BG/U 500 Grinding machine tpe BG/U 500

BERKOL® circular grinding machine type BG/U 500

The semi-automated BERKOL® grinding machine Type BG/U 500 is suitable for grinding all types and brands of top rollers used in a spinning mill. The precision guides with dust tight covers guarantee a long life and minimum maintenance. With the specially developed grinding stone and versatile setting possibilities, the desired surface roughness can be attained without any problem. A balancing device for the grinding stone is integrated in themachine. A number of special tools are available for the various top rollers. A dust extractor is included in the scope of supply.

The grinding machine offers the following possibilities:• Grinding between centers and hollow points for long cots• Grinding with top roller attachment for roving, ring- and air jet spinning top rollers• Grinding on a mandrel for OE nip rollers• Taper grinding (conically) for special use like detaching rollers for combers• A wide range of application

Grinding speed

Spindle speed

Traversing speed

Grinding stone dimensions

variable

diameter

width

speed

quality

150 - 900 rpm

20 - 700 mm/min

225 mm

20 mm

2800 rpm

BERKOL® special

Grinding range

Center grinding

Grinding with top roller

attachment

max. distance between centers

max. grinding length

max. diameter of cover

min. diameter of cover

max. diameter of cover

max. length of top roller

520 mm

500 mm

140 mm

19 mm

65 mm

200 mm

General

Balancing device

Dust extractor

Space required

Connected load

Weight

Country of origin

integrated

included

Switzerland

10 m3/min

2 x 3 m

5 kW/400 V

490 kg

BERKOL® circular grinding machine BG/U 500


Module L (LARGE)

• Large universal loading and

unloading magazines

• Up to 2 hours of operator

free operation (depending on

diameter of cover and filling

degree of magazine)

• Loading capacity of up to

450 axles (depending on

diameter of cover)

Module M (MEASURING)

• Integrated measuring system

• Makes differential grinding possible

• Sorting function without grinding

• Grinding to size

Module B (BERKOLIZING)

The top roller covers are evenly

berkolized directly after grinding

with no additional labour costs. The

automatic module is electronically

controlled and works synchronised

with the grinding process.

Berkolizing brings the

following advantages:

• Fewer laps

• Less spindle downtime

• Fewer damaged covers

• More economical production

Easy and ergonomical

loading /unloading

Integrated measuring system Fully integrated berkolizing module

9594 supergrinder supergrinder

The fully automatic grinding system

The BERKOL® supergrinder is based on a modular structure, designed for automatic grinding and berkolizing of ring, roving and air jet spinning top rollers.

The basic machine can be supplied in accordance with customer requirements with modules for measuring the covers, with large magazines (up to 450 top rollers) and with berkolizing module. The measuring system offers different measuring and sorting programs, thus ensuring an efficient quality control of the top rollers.

BERKOL® supergrinder

Thanks to the specially developed grinding stone and the versatile setting possibilities, optimal roughness values can be obtained. Due to latest technology the capacity grew up to over 350 rollers/hour (depending on cover surface roughness to be achieved).

Machine operation by user-friendly touch-screen panel with integrated multi-language operation guidance in German, English, Chinese, Italian, Spanish, Portuguese, Russian and Turkish.

The dust extraction device is included in the scope of supply.

Machine operation by userfriendly

touch-screen panel with multi-language

operation guidance

BERKOL® high performance

grinding stone

Modular structure


9796 BERKOLIZER BERKOLIZING

BERKOL® the surface treatment: berkolizing

• Simultaneous berkolizing and loading of top rollers, thanks to a revolving drawer, increases the efficiency in the roll shop• Especially developed 1’000 Watt UV lamp and reflectors guarantee short exposure of cots due to highly concentrated and even irradiation intensity• Long life and efficiency of UV lamp is strongly enhanced due to the uninterrupted “running” of the Berkolizer, due to minimal heat build up properties of the UV lamp• Lower energy consumption and low maintenance cost reduce operating cost considerably• Compact and user friendly design• A small investment with very high benefits• Environment friendly and proven process to improve the performance of any cots

Laps can form on the top roller covers dependingon the fibre material being processed, the climate and the spinning machine. To avoid these laps, the covers used to be treated with lacquers, hydro-chloric acid solutions, iodine and similar. Thesetreatments are time-consuming, expensive and frequently environmentally harmful. Sometimes they even corrode the metal.

Nowadays, these agents tend to be avoided. They have been almost completely replaced by surface treating by means of UV-radiation, so-called berkolizing. The treatment is applied after grinding the covers, providing artificial ageing of the rubber surface and reducing the abrasion coefficient. Even with regular application, the cover material does not become neither hard nor damaged. But optimal dosage of the radiation time is very important for success.

This process has the following advantages:• easy and fast• inexpensive• environmentally friendly

BERKOL® BERKOLIZER

Berkolizing top rollers influences the running characteristics of spinning machines positivelyin many aspects. However, berkolization cannot improve a poor cot quality and poor finish.Perfect grinding is absolutely essential before berkolizing, as well as the time of berkolizingthe top rollers.

Our customers obtain the following advantages from berkolizing:• reduction of the run-in problems of newly ground coves• good running properties• better yarn quality• less labour requirement• cost reduction

The duration of the berkolizing is decisive for success. It should always be as short aspossible. Berkolizing for too long reducesthe friction coefficient of the covers whichleads to thread breaks.

The duration of the treatment depends on:• application (ring spinning, combing, etc.)• climate• fibre material• cover properties• type of berkolizing machine

The wide range of these influencing factorsshows that each customer has to definethe optimal berkolizing time through trials.In the instruction books for the manual andautomatic berkolizing machines, BERKOLgives recommendations and standard valuesfor the relevant applications.

unberkolized berkolized


9998 Testing device Measuring device

Concentricity tester

Even yarn of top quality can only be spun with perfectly smooth-running top rollers. BERKOL®’s testing devices are crucial for quality assurance. They reveal faults, thus helping to save money.

The top roller testing device form BERKOL® is for checking the parallelism and smooth running of all the top rollers of a spinning mill.

The BERKOL® testing device is a precision instrument. It is delivered in a solid, practical hardwood box which protects the device form dust and dirt.

Measuring range:Roller diameter 20 mm to 100 mmMax. roller length 450 mmMeasuring sensor 0.8 mmPitch 0.01 mm

The hardened and ground contact rollersare driven by a smooth-running electro motor.

The freely moving measuring carriage runs on a precision guide, free of play. The spherical joint supports allow fast, exact positioning of the precision measuring sensors.

Faults concerning smooth running, parallelismor wear and tear can be measured with0.01 mm accuracy.

BERKOL® surface finish measuring deviceBERKOL® testing device

Roughness tester

The surface texture has a great influence on the running behaviour of the top roller covers. It can be checked with the lip, with a magnifying glass or witha surface finish measuring device. A surface finish measuring device has the great advantage that the coarseness can be quantified and documented with a measured value.

The Perthometer which BERKOL® supplies is particularly suitable for measuring soft materials.


101100 Hardness testing device Lubrication devices

SHPSA R 35 M

The hardness of top roller covers has a greatinfluence on the draft performance and thus on the yarn quality. It is usally measured in Shore A. The standard measurement in accordance with DIN 53505 prescribes a coating thickness of minimum 5 mm and a press-on force of 1 kg. The measurement on a drum therefore usually differs from the effective value.

The BERKOL® hardness checking device is fitted with an appliance which guarantees the right press-on force.

BERKOL® lubrication devicesBERKOL® shore hardness testing device

Technical progress in a modern spinning mill with high performance machines and a reduced number of staff needed to run them, requires rational maintenance of all production machines and appliances.

In close cooperation with users, we have developed efficient lubrication appliances which surpass conventional manual devices by far.

Regular lubrication considerably lengthens the working life of the bearings.

BERKOLUBEUp to 800 top roller bearings for ring spinning machines or roving frames can be lubricated per hour with this pneumatic lubrication device which ensures an exact dosage of the required amount of grease.

Various take-up tools and lubrication nozzles are available to adapt to the different top roller types.The device can be adjusted very quickly to the various top roller types.

Technical data• Amount of grease per bearing adjustable form 0.2 cm3 to 2.0 cm3

• Capacity of 600 to 800 top roller per hour• CE-conforming with pneumatic two-hand safety control• A 25 kg grease container is sufficient for 20’000 to 22’000 top rollers• Grease standard supply: Klüber Staburags NBU 12/300 KP

Lubricating unit BOS-01The BOS-01 is an inexpensive manual lubrication device for all axially-lubricated top rollers. The standard equipment is suitable for top rollers with a tube diameter of 19 mm and a maximum of 80 mm. Appropriate tools can be provided for other top roller types.


Since 1835 we successfully serve our customers in the textile industry

Bräcker is built on a solid foundation. In conjunction with the sister companies, Graf, Novibra and Suessen,Bräcker is securely embedded in the network of totalsolution and application expertise in yarn processing.

Graf www.graf-companies.com Novibra www.novibra.comSuessen www.suessen.com

Bräcker ProductsSwiss Premium Quality

Bräcker AGObermattstrasse 658330 Pfäffikon-ZürichSwitzerlandPhone +41 44 953 14 14Fax +41 44 953 14 [email protected]

www.bracker.ch

Bräcker S.A.S.132, rue Clemenceau68920 WintzenheimFrancePhone +33 3 89 27 00 07Fax +33 3 89 27 52 [email protected]

PR 10042/ 2014 © Copyright by Bräcker / Subject to modification without prior notice

short staple manual€¦ · pes, cv, blends and pac 25 spinning of synthetic ﬁbres pes, pac and...

Documents