Increasing Speed of Yarn Spinning

8/8/2019 Increasing Speed of Yarn Spinning

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Increasing Speed of Yarn SpinningTE 589AProject

Vikram J Khona

Under the Direction of:

Dr. Michael S. SlocumAdjunct Assistant Professor

N.C.S.U.

Dr. Timothy G. ClappProfessor N.C.S.U.

Problem

The system is the ring-spinning machine. Thesystem consists of the spinning elements andthe accessories for assisting the spinningelements. The fibers or filaments are giventwist to form the yarn. The yarn passesthrough the traveller and gets wound on the

package. The traveller goes around the ringinserting twist in the yarn, and there by theyarn being formed.

The problem lies in the fact that the speed of the spindle is restricted to a about 25,000 rpm.The speed of the spindle is restricted by thering and traveller. The friction between thering and traveller restricts the speed of thetraveller on the ring-spinning machine. If thespeed is increased more than 25,000 rpm theheat generated due to friction burns thetraveller and the system collapses. The systemhas to be improved to get higher spindlespeeds there by having higher production.

Contradiction Present in the System



The contradiction present in this system is a technical contradiction. The contradiction here isthat if the speed of the spindle, which in turn the speed of the traveler is increased, the heatgenerated due to friction increases which in turn wears the traveller.

The contradiction can be transformed into a physical contradiction, which is that if there should

be friction present so that the yarn is wound on the package but it should not be present as itwould heat up the traveller and wears it out.

Ideality

The ideal solution for this system would be that the yarn is formed at a high spindle speed say100,000 rpm, which means high production and the yarn having excellent properties.

The ideal final result can be achieved by removing the harmful function which it the frictioncreated between the ring and the traveller. This can be achieved by making the ring and traveller with a friction less material or by just eliminating the traveller.

It can also be reached by replacing a particular element of the spinning system. The traveller andthe ring can be replaced by some other mechanism where by the twist is inserted to the materialand the yarn being formed.

Contradiction Matrix

The contradiction present in this system is a technical contradiction. The contradiction matrixcan be used to resolve the contradiction.

Using the contradiction matrix there were about 3 parameters which most suited the

contradiction. They were; Productivity (39) Durability of Moving Object (15) Speed (9) Waste of Substance (23)

Using the contradiction matrix the possible solution sets were determined and the best possiblesuited principles were the principle 35.Transformation of physical and chemical state of theobject and 28.Replacement of the mechanical system.

The principle 35 says to change the state of the object, which can be changing the hardness,density and/or surface finish of the ring and/or traveller.

The principle 28 says to change the mechanical system, which can be to change the mechanicalsystem to an electromagnetic system so that the friction between the ring and the traveller isreduced.

L evels of Innovation



To find out which level of innovation this system is in at present, various factors of thelevels of innovation was considered. After considering the factors the system is in between level3 and level 4.

y There are a lot of trial and error tests conductedy

There exists a strong sharp technical contradictiony The scope of knowledge applied so far is with the same field and from differentfieldsy There was strong characteristic change in the systemy There is a considerable impact on the knowledge of science

Innovative System Questionaire

y Information

y System nameThe system name is the ring-spinning machine. The machine consists of thespinning elements, which are the ring and the traveller and the auxiliary elements.y Primary functionThe primary function of the system is to form yarn by introducing twist to thematerial, which is either fibers or filaments.y Current or desired system structureThe system has the ring and traveller arrangement. The ring is mounted on a ringrail, which is driven by a differential. There is a lappet through which the materialis guided to the traveller. The material flows from a package through guides and

passes through rollers.y F unctioning of the systemThe material is unwound from the package, which is placed on the back of the

package with tension. The material passes through guides and them to the back roller and then to the front roller. The material is drafted between the two rollers.The drafted material is then passes though the lappet and then to the traveller which is mounted on the ring. The twisted yarn is then wound on another packagemounted on the spindle. The spindle is driven positively.

The spindle is rotating at around 25000 rpm. The yarn is passed through therollers and then guided down with the lappet and then passed though the traveller and gets wound on the package. The traveller revolves around the ringintroducing twist. The traveller is negatively driven by the spindle.y System environment

The whole system interacts with the air, which surrounds the machine.The system interacts with the operator

The system interacts with the other machines of same kind and other kindsThe system has a power source to run the motor

y Available Resources



y Substance resourceThe substance resources that are present in the system are the ring and thetraveller, the spindle, air, moisture, material, waste, etc.y F ield resourceThe field resources present in the system is the mechanical field which creates the

frictional and a mechanical field which produces the yarn.y F unctional resourceThe functional resource is the function of the mechanism by which the ring andthe traveler produces the yarn by twisting the material.y Time resourceThe time resource is the time required to produce the yarn.

y Information of Problem Situation

y Desired improvement to system and/or function to eliminateThe improvement to be achieved is to increase the speed of the spindle, which in

turn increase the speed of the traveller making the system more productive.Another improvement to be achieved is to make better quality yarn.y Mechanism that causes drawback The drawback of the system is its speed capability. The speed is limited and theneed has reached to increase the speed of the system to make it more productive.The friction between the ring and the traveller is reach to an extent, which causesthe traveler to burn out. The drawback is in the ring and traveller mechanism of the system.y H istory of the problemThere have been a lot of studies conducted on the effect of increasing the traveller speed on the yarn quality and on the life of the traveller. The system has

developed form stages where the speeds were slower and it has reached to a stagewhere the spindle speed is 25000 rpm.y Secondary and tertiary problemsThe secondary problem to be solved is to reduce the tension of the yard in thespinning range so that there is no end break. The tension should not exceed thetensile strength of the yarn. If so the yarn will break and the system will fail.

y Changing the System

y Allowable changes to the systemThe allowable change in the system is to maintain the twisting mechanism of

using a ring and traveller or similar system where the twist is inserted in the sameway as the ring and traveller system.y L imitations to the changes to the systemThe change in the system should not be expensive. The cost of the changes shouldnot increase the cost of making the same production with the increased capacityof old systems.



The changes should be in technically feasible for the present time. It should beachievable in the present

y Criteria for Selecting Solution Concepts

y

Desired technological characteristicsThe desired technological characteristic that the system should have is amechanism by which the twist is inserted in the same fashion how it is inserted bythe ring and traveller mechanism.y Desired economical characteristicsThe desired economical characteristic the system should have is that it should be

practically feasible to be commercially viable. The cost of the changed systemshould be profitable to implement.y Desired timetabley E xpected degree of noveltyThe system should be different and new in a way that it has better productivity

and quality of yarn produced than the old system.y Other The system should not consume a lot of floor space.

y H istory of Attempted Solutions

y Previous attemptsThere had been previous attempts made to improve the speed of the ring andtraveller system. These attempts have improved to an extent. The main difficultyfaced by these attempts is with the traveller burning out.y Other system that exhibit similar problems

Other systems that exhibit similar problem was not successfully identified.

Algorithm of Inventive Problem Solving - ARIZ

1 Mini Problem F ormulation

1.1 Key problem

(+) Increasing productionIncreasing the speed of the spindle

(-) Traveller heating up and wearing out

The problem is the heat generated because of friction between the ring and the traveller is highwhen the speed of the spindle is increased causing the traveller to burn-out.

1.2 Useful function





If the spindle speed is low then (+) it reduces the production but (-) does not heat up the traveller.

1.11 F ormulate the mini problem

The system is to make yarn by twisting the material, with the help of the ring and the traveller

where the traveller is driven negatively by the spindle.

IC-1: If the spindle speed is very fast then (+) the production is very high but (-) the traveller burns out.

IC ± 2: If the spindle speed is low then (+) it reduces the production but (-) does not heat up thetraveller.

2 The Pseudo- F undamental Contradiction F ormulating and Resolving

2.1 F ormulate the pseudo-fundamental contradiction

The speed of the spindle should be high for producing the yarn fast and should be low toeliminate the heating of the traveller due to friction

2.2 Resolve the pseudo-fundamental contradiction

The separation principles are used and it can be resolved by separating the ring and the traveller in space. This way there is no friction between the ring and traveller and the spindle speed can beincreased.

3 Conflict E nforcement

3.1 E nforce the conflict from IC-1

Very high speed of the spindle so that the production is willingly increased. This formulationgives the importance of speed in production.

3.2 E nforce the conflict from IC-2

To produce yarn without the rotation of spindle. This is possible if only the traveller is drivenwith another source and not form the spindle.

4 F

ormulating Directions for Solutions

4.1 F ormulate the model of problem for the conflict IC-1

The speed of the spindle increases the speed of the traveller which increases the friction created between the ring and the traveller.

Increase in production



Increasing spindle speedTraveler heating up and wearing out

It is essential to introduce an resource which prevents the heating up of the traveller andmaintains the speed of the traveller.

4.2 F ormulate the model of problem for the conflict IC-2

The low speed of the spindle keeps the traveller cool, but does not increase the production.

L ow productionDecrease in spindle speed

Traveler not heating up

It is essential to introduce a resource, which provides the traveller energy to have high speed and

the same time keeps the traveller from wearing out.

5 Using Substance- F ield Transformations

5.1 Render the initial SU- F ield model for the problem on step 4.1

The SU-field model made with IC-1 is that the work piece is the ring in which the traveller is placed. The tool is the traveller and the field created it the friction. It is a mechanical field. Thereis a harmful relation ship between the work piece and the tool creating friction. There is a usefuland harmful relation ship between the traveller and the field friction as it is needed for windingand not needed as it causes wear of the traveller.

5.2 Try to solve the problem with SU- F ield model from step 5.1



In order to remove the harmful functions the 76 standard solution set was referred and the SU-field model was solved. A field has to be added between the ring and the traveller to resolve theharmful effect. A substance is added between the field created and the traveller to direct theharmful function to an intermediate substance and thus the SU-field model is solved.

The substance that is added between the field (friction) and the traveller is a void substance. Thefield added between the ring and the traveller is a electromagnetic field.

6 Operational Zone Analysis and Resources Discovering

6.1 Determine the operational zones (OZ)



6.2 Determine the operational and resource time (OT and RT)

The operational time and the resource time could not be determined. But it is very short as thespeed of the machine is very high. It is in the terms of milliseconds.

6.3 Operational zones picture

The operational zones picture is shown in the figure above.

6.4 Describe the operational zone picture

The conflict present here is in between the ring and the traveller. The ring and the traveller comein contact with each other in the inner surface of the ring as shown in the figure.

6.5 Mark useful, harmful, insufficient, and excessive substances, fields, properties, processesand flows.

Useful function, but insufficient;

To produce the yarnTo produce the yarn at a fast rate

H armful functions;



Generation of frictionWearing of the traveller

6.6 Draw the relative picture of events going on in the OZ¶s

ML

P modeling (was)

In the M L P modeling we can see clearly what is going on in the zone of conflict. We can use thesmart little people to simulate the process. There are two groups of smart little people¶s. TheSL P1 is the group in the traveller, and the S L P2 are the group in the ring. When the ring and thetraveller is in working the S L P2 and the S L P1 fight eachother killing the S L P1, causing the wear of the traveller. This is because S L P1 are weaker than the S L P2.

ML P model (should be)



In the should be model of the M L P modeling we can resolve the conflict by introducing another group of smart little people in between the two, preventing the conflict. The S L P3 will not letSL P1 and S L P2 come in conflict and there by the wear on the traveller can be avoided.

6.7 E stimate the resources

The resources that is present in the system are ring, traveller, material, spindle, package, air,waste fly, temperature, humidity, moisture, pressure, oxygen, balloon control rings, lappet, etc.

7 Initial Ideal Result (IIR) F ormulation

7.1 Describe the IIR

F or IC-1 F or IC-2X-resource X-resourceWithout system complication Without system complicationWithout harmful consequences Without harmful consequencesPrevents overheating of the traveller Provides energy to the traveller to produce

yarnMaintains the force required to produce theyarn at a fast rate

Maintains complete absence of the heatgenerated on the traveller

7.2 Step back from IIR



It can be ideal that the molecules of the traveller dissipate the heat to the environment or the ringwith the help of a void substance.

7.3 Create a preliminary portrait of X-Resource

The x-resource should be able to pass the heat generated from the traveller to the environment.

The x-resource should be able to allow easy movement of the traveller around the ring.

The x-resource should be easy to use.

7.4 Take resources from step 5.7 as X-Resource

The resources that are present in the system that can act as the x-resource is air and moisture

7.5 F ind a method to perform the X-Resource actions formulated

The x-resource can be a magnetic field that can repel the ring and the traveller so that there is nocontact between the ring and the traveller and thereby avoiding friction.

7.6 Try to find a trade-off solution of the problem with minimum deviations from IIR requirements

The solution that can be achieved is that by using a electromagnetic field between the ring andthe traveller so that the ring and the traveller repels there by preventing them to come in contactwith each other.

7.7 Choose the main resource and formulate the enforced IIR

The main resource used here is a electromagnetic field. This is not an available resource. Thering and the traveller can be oppositely charged preventing them to come in contact with eachother.

8 F undamental Contradictions F ormulating

8.1 F ormulate a brief fundamental Contradiction

The x-resource should be present between the ring and traveller at all the time to prevent them to

contact each other to avoid heating, but it should not be present to provide some friction for theyarn to wind in the package.

8.2 F ormulate the fundamental contradiction for process

The contradiction in the process it that the friction created between the ring and traveller duringspinning causes heat and friction is also needed to wind the yarn in the package.



8.3 F ormulate the fundamental contradiction for macro-state

8.4 F ormulate the fundamental contradiction for micro-state

8.5 F ormulate the fundamental contradiction for flow

The fundamental contradiction for flow is that the heat energy should flow to the environment but should not pass to the rest of the traveller.

9 F undamental Contradictions Resolving

9.1 Resolve the brief fundamental contradiction

The x-resource should be of such properties that it should conduct heat to the ring from thetraveller but at the same time it should be viscous to provide some resistance to the movement of the traveller in the ring.

9.2 Resolve the fundamental contradiction for process

The fundamental contradiction for process can be resolved by using a substance or a field thathas both the required properties.

9.3 Resolve the fundamental contradiction for macro-state

9.4 Resolve the fundamental contradiction for micro-state

9.5 Resolve the fundamental contradiction for flow

The flow of the energy is resolved by suing a substance that transmits the heat energy form thezone of conflict to the environment.

10 The Ideal F inal Result (I F R) F ormulating

10.1 F ormulate the I F R for the brief fundamental contradiction

The additional resource should provide the necessary characteristics of the necessary x-resourceduring the spinning process to prevent the heating up of the traveller.

10.2 F

ormulate the IF

R for process

The ideal final result of a process should be that there is no friction created to generate heat, butthere should be friction to wind the yarn in the package.

10.3 F ormulate the I F R for macro-state

10.4 F ormulate the I F R for micro-state



10.5 F ormulate the I F R for flow

The ideal final result for flow is that it should transmit all the heat generated by the traveller tothe environment.

11 Solving the NewF

undamental Problem in IF

R F

ormulation

11.1 Solve new fundamental problem in I F R using resources discovered on step 6.4

No new fundamental problem.

11.2 Solve new fundamental problem in I F R using SU- F ield Transformations

No need to solve if there are no problems.

11.3 Solve new fundamental problem in I F R using the final portrait of required problem

solving phenomenon

No need to solve.

11.4 Solve secondary problems if necessary

No secondary problems.

Conclusions

The TRIZ tools were used to solve the problem of improving the productivity of ring spinning.

Ring spinning technology is very important and un-substituable until now. It has reached amatured state. TRIZ tools were used to improve the system and the results are stated;

Change the hardness, density, material and/or the surface finish of the ring and traveller. Use a field between the ring and the traveller. The field can be a magnetic field. Use a void substance between the ring and the traveller. The substance could be air or

lubricant. Suspend the ring in a electromagnetic field without the traveller, which gives the same effect

as a ring and traveller and there is no question about friction to hear up a traveller since there isno traveller present.

These solutions are applicable either at present or in a future date. The last solution where in aelectromagnetic field is used to suspend the ring in space is a solution which can be achieved in afuture date as the present technology is not applicable.

Thus by using the TRIZ tools the solution of the problem is achieved with a higher level of innovation.



Documents

Increasing Speed of Yarn Spinning