The Perfect Combination – The Rieter Rotor System - …€¦ · · 2013-03-25ICAC 62nd Plenary Meeting Gdansk, Sept. 7-12, 2003 Rieter Textile System Page 1 (7) Speaker: J Bischofberger

ICAC 62nd Plenary Meeting Gdansk, Sept. 7-12, 2003 Rieter Textile SystemPage 1 (7) Speaker: J Bischofberger

The Perfect Combination – The Rieter Rotor System

J. Bischofberger, Rieter Machine Works Ltd., Winterthur Switzerland

1 C 60 Card – a new dimension in carding

If we look at the development of cards in recent decades, we can certainly see considerableadvances in production performance. With the C 60, a high-performance card has nowbecome available which has been reconceived and developed from scratch. The newdimensions therefore refer not only to its geometric characteristics.

1.1 Requirements

As early as the conceptual phase, the requirements were discussed and initial ideas for thedesign of the new card were outlined in a workshop with experienced customers. Three mainpoints emerged from this:

• Reducing the capital and operating costs of the carding process

• Quality: the fact is that in the keenly contested yarn market our customers are beingconfronted with demands to meet ever higher quality standards. At the same time, cottonis tending to reach spinning mills in increasingly poor quality. Higher demands on thetechnological qualities of cards, and especially their ability to reduce trash content, aretherefore understandable

• Flexibility: If they are to be successful in future, a large proportion of spinning mills willdepend on being able to offer a flexible product range

With regard to this final point, it is worth mentioning that we have already successfully metthis requirement for some years in the case of our blowroom with the VarioSet concept.

Fig. 1, 2, 3, 4

1.2 Higher output

The C 60 Card enables output to be increased by some 50% compared to the C 51Hi•Per•Card, depending on raw material and yarn type. This is the most important – althoughnot the only – response to the demand for a reduction in the cost of carding.

Fig. 5


We wish to mention here that the high production performance has been achieved throughthe following features, among others:

• Increase in working width by 50% to 1500 mm

• Reduction in cylinder diameter and increase in take-off roll diameter

• Improved preparation for carding by means of an opening unit in the chute

Boosting output by increasing working width means that there is no reduction in cardingquality. The fiber density laid down on the cylinder is exactly the same on the C 60 at150 kg/h as on a conventional card at 100 kg/h.

Fig. 6

On conventional cards with a working width of 1 meter, high production rates have to be runat high sliver weights in order to keep the delivery speed within permissible limits (e.g. sliverweight > 6.6 ktex at 120 kg/h). High sliver weights mean high material density on the take-offdevice, which has a negative impact on quality. By its very nature, so to speak, the C 60delivers a 50% heavier sliver with the same amount of material laid on the cylinder. Initialexperience has shown that in most cases the usual sliver coiler (CBA-4) can be used and theweight of the slivers can be reduced again to the usual level in the subsequent draftingpassage. If a lighter sliver (3.5– 6 ktex) has to be delivered for any reason, even at highproduction rates, a coiler with an integrated non-levelling drafting system (SB module) can beused. The autoleveller version (RSB module) is used for the OE direct process application.

1.3 Consistently high quality

We have repeatedly pointed out in the past that not only high quality, but above all consistentquality, is important. We have made this possible by means of pioneering developments andmill-oriented products, such as IGS-classic and IGS-top for automated grinding of thecylinder and flats. Equipment of this kind can, to a large extent, correct the negative influenceof clothing wear.

Fig. 7, 8

However, conceptual and design measures which keep the quality of output high and stableare at least as important. The following features of the C 60 are among those with this inmind:

• An optimized chute feed system with an opening roller and infeed via a feed trough

Fig. 9

• Uniform lap feed by means of active compression of the material

Fig. 10

• The small diameter of the cylinder reduces the effect of temperature fluctuations on thesize of the carding gap, thus permitting narrower settings without running any risk

Fig. 11


The high-precision and in some respects innovative manufacture of the machine provides afurther basis for stable and reliable operation.

Fig. 12

1.4 Manufacturing rotor-spun yarn

The C 60 is an excellent card for the rotor yarn process, where primarily low trash and dustcontent in the card sliver affects not only yarn quality but also the productivity of the rotorspinning machine. With the opening unit in the chute and an effective licker-in, trash and dustare exposed and for the most part already removed in the licker-in zone. In the carding zone(cylinder/flats) much more intensive trash removal takes place than in cards of conventionaldesign. This is due to the influence of the increase in centrifugal forces resulting from thesmaller cylinder diameter and higher cylinder speeds.

With the RSB-module coiling unit, a carding system with short-term levelling is now availablefrom Rieter. This special coiling unit is essentially a complete autoleveller drawframe from thewell-known RSB series. It is the result of close cooperation between our drafting and cardingspecialists. Maintaining counts at the beginning and end of a can is ensured virtually to thelast centimeter by the ingenious integrated automatic control of the card and the coiler.

Fig. 13

The C 60 delivers a 50% heavier sliver than conventional cards, with a better quality due tothe blending effect of the larger width. It is therefore ideally suitable for the direct process.

An inherent problem of machines with high production rates is their major impact on theoverall productivity of an installation. Whereas 15 cards were required for an output of600 kg/h 20 years ago, only 4 or 5 are required now. Instead of losing output of 7% when acard failed, this figure is now 20–25%. This was an important point both for us and for ourkey customers at the beginning of the conceptual phase of the C 60. The consequence is astrictly modular design with the following features:

• A simple device enables the licker-in to be replaced as a unit

• The entire set of flats can be removed and replaced as a whole (the flats can also beremoved individually from the machine, of course)

• The delivery unit can be completely removed from the machine

Fig. 14

1.5 Top-quality slivers

Almost 20'000 drawframes in the SB and RSB series have been delivered to nearly100 countries all over the world in recent years. 20 years of development experience withautolevelling systems are one of the reasons for the worldwide success of our drawframes.Rieter autoleveller drawframes deliver slivers of the highest quality to the subsequentproduction processes.


2 R 40 rotor spinning machine – maximum performance forprofitable rotor spinning

The R 40 rotor spinning machine offers our customers in spinning mills the opportunity toacquire a machine, which represents a combination of the best components available. Thismachine offers considerably enhanced potential for very high productivity by virtue ofimproved spinning stability and maximum length. Further improvements ensure low energyconsumption compared with similar machines.

2.1 Proven basis as a combination of trend-setting systems

The SC-R spinning box used here is a further development of the most widely used(2.5 million units) and long proven spinning box concept. This spinning box is the centerpieceof an automated rotor spinning machine featuring a trend-setting concept with both piecingand package change integrated in one robot. The machine concept has been the subject ofongoing development efforts over many years and has attained a high level of reliability.

Fig. 15

2.2 High productivity due to high spinning stability

Newly developed spinning elements allow yarn characteristics according to the specificapplication.

Fig. 16

As a result of the new spinning geometry with optimized take-off angle on the R 40, it is alsonow possible to work with low twist factors compared with the parameters customary todayon other rotor spinning machines. This reduction in yarn twist enables higher productivity tobe achieved as well as the much softer final fabric quality called for, especially in knitting.

Fig. 17

2.3 Higher efficiency as a result of large units and intelligent logistics

In common with its predecessor model, the R 40 has an especially wide gauge of 245 mm,which permits the use of larger feed cans than on other machines.

Fig. 18

Large package formats also offer advantages. The R 40, in common with its predecessormodel, enables cylindrical packages with diameters of up to 340 mm to be produced. Thiscorresponds to a package weight of up to 5 kg, enabling savings to be made amounting tomore than 20% of the cost of package handling and transport as well as empty tubes both inthe spinning mill and in downstream processing in weaving or knitting mills.

Fig. 19


2.4 Reduced drawframe requirement and improved yarn quality due to coarse-count slivers

Technologists' experience repeatedly confirms that yarn uniformity is improved in rotorspinning by reverse doubling of the fibers in the rotor. This effect is reinforced by high drafts,i.e. by the use of heavy feed slivers.

Rieter customers who use feed slivers of 6 ktex and more appreciate the improvement in theCV value. The design of the R 40 even allows feed slivers of up to 7 ktex to be used. With apotential drafting range from 40 to 400-fold on the R 40, almost all yarn counts can thereforebe spun from the same feed sliver.

In addition, savings in drawframe capacity can be achieved by the use of higher sliverweights in preparatory operations.

2.5 High production speed under the control of proven automation systems

The modular AERObotic concept of Rieter's rotor spinning machines incorporates high-precision, specialized, electro-pneumatically actuated operating modules. These areoperated by a modern processor control system. The control system enables processes tobe performed largely in parallel. The resulting time savings contribute to the high efficiencylevels, which can be achieved with the R 40.

Fig. 20

2.6 High rotor speeds and lower energy consumption

The R 40 can achieve top performance with rotor speeds of up to 150’000 rpm. At the sametime steps have been taken to reduce energy consumption and thus running costs.

Fig. 21

The section modules of Rieter machines are manufactured with high precision and can beassembled extremely accurately on-site.

The machine can therefore be operated with significantly lower contact pressure along thewhole of its remaining length at the same time. Lower belt contact pressure means reducedbelt wear and reduced energy consumption.

Fig. 22

The main fan, the second-largest consumer of energy on the rotor spinning machine after therotor drive, has also been improved.

Fig. 23

It therefore requires about 30% less power than competitor machines, even for the fullmachine length. Conclusion: The R 40 machine is the basis for profitable rotor spinning.


Fig. 24

3 Summary

3.1 The perfect combination – the Rieter Rotor System

As part of the Textile Division, Rieter Spun Yarn Systems is the leading integrated supplier ofinstallations for manufacturing yarns from cotton, man-made fibers and blends for all textileapplications.

In the field of rotor spinning, Rieter currently offers a selection of machines with widelydiffering degrees of automation. The product range here extends from semi-automaticBT 903 open-end machines with electronic piecing units to fully automated R 40 rotorspinning machines for very high rotor and delivery speeds.

Rotor spinning technology is the second most important yarn manufacturing process afterconventional ring spinning. Rotor-spun yarns account for some 35% of global short stapleyarn output. This proportion will continue to rise in years to come.

Rotor-spun yarns today have a very diverse range of applications. The main emphasis is onyarn counts between Ne 8 and Ne 34. This extends from denim yarns to fine-count weavingyarns for bed linen or fine count knitting yarns, for example for T-shirts. Regenerated fiberscan also be used extensively for medium and coarser yarn counts. One of the strengths ofrotor spinning is the use of short cotton fibers.

Rieter is currently the only manufacturer worldwide who can supply complete and fullyautomated rotor spinning installations. There are many advantages in this, since thecustomer has a single contact throughout the entire project phase.

3.2 Ongoing further development

Rieter introduced two new product generations to the textile industry: The C 60 high-performance card and the new R 40 rotor spinning machine. Both products stand forinnovation and maximum production performance, and add up to a perfectly coordinatedsystem for manufacturing top-quality rotor-spun yarns.

Fig. 25

Together with the VarioSet blowroom and the SB-D 15 and RSB-D 35 drawframes, the C 60high-performance card and the R 40 rotor spinning machine make up the Rieter RotorSystem.

This new system allows maximum productivity and also offers potential for the future throughthe possibility of process shortening.

Fig. 26

J. BischofbergerICAC, September 10, 2003 Rieter Textile Systems1

Buying the right quality at the right time

Production program as demanded by market

RIETERBlowroom

Optimal mixing of various materials

Choosing machines with high yield

Minimizing production costs

Buying equipment designed for flexibility

Your choice Decisions on

Yarn Producer Decisions

Blowroom Concept


The Rieter Blowroom is different

VarioSet Cleaning Field2-stage cleaning

Blowroom Concept


The Rieter Way - effective and gentleD

egre

e o

f C

lean

i ng

Bale opener Pre-cleaner Fine-cleaner

Required degree of cleaning in blowroom

cards

Blowroom processes

No aggressivefine-cleaningnecessary

Blowroom Concept


Alternative Working Points for same Cleaning Effect

1 2 3 4 5 6 7 8 9 100.0

0.2

0.4

0.6

0.8

1.0

Relative amount of waste

Inte

nsi

ty

•Less neps

•Whiter waste

•Darker waste

•More neps

Blowroom Concept


The New Dimension in Carding

Card C 60

• Designed for rotor and coarse ring yarn

• High and constant quality with cotton and manmade fibers at high production level due to1500 mm wide cylinder

• Highest production in the history of carding

• Maintenance drastically reduced thanks to modular design

• Low space requirement.

• Choice of autoleveller RSB coiler for highly productive card to open-end direct process

• High trash reduction due to reduced cylinder diameter


50% higher Production with the same Fiber Density

Card C 60

at the Technology Elements

VbCircumferential speed

Conventional card

Carding area B

Vs = VbCircumferential speed

High-production card C 60

Carding area S = B

+50%

50% Higher carding area


Integrated Grinding System (IGS- classic)

Card C 60

For Output

No downtime for cylinder wire grinding

Fully automated, computer-controlled system

For Quality

Ensures constant quality overlifetime of cylinder wire

Ideally suited for latest wire technology


IGS- classic improves Sliver Quality and prolongs

Card C 60

Lifetime of Cylinder Wire

Conventionally3 - 4 times

3-4 x grinding

Rounded carding edge

400x

IGS-classic400 times

Sharp carding edge

Microscopepicture

Cylinder wire sharpened by IGS-classic


Optimal Material Preparation in Chute

Card C 60

«A»

Feed roll

Feed trough

Opening roll

Gentle fiber treatment by adjustable feed trough position


Optimal Material Preparation in Chute

Card C 60

Active compression results in optimal mat structure for highest sliver quality


Smaller Dimensions Higher Precision

Card C 60

Example: thermal expansion of cylinders

ColdCold

Warm

>Distance a Distance b


Power Consumption

Card C 60

6.0

8.0

10.0

12.0

14.0

16.0

30 40 50 60 70 80 90 100 110 120 130 140 150

Card production kg/hr

kW Card C 60DK903


The Best OE Direct Process

Card C 60

• Highest quality due to same fiber density as in conventional card

• Constant sliver quality with world’s best drawframe integrated

• „Naturally“ high sliver weight permits optimal draft


Designed for minimum Maintenance Downtime

Card C 60

A comprehensive set of tools and spare modules drastically reduces production loss

Licker-in module

Flat module

Doffer module


The reliable Basis: The Rotor Spinning Machine R 20The new Core: The most advanced SC-R Spin Box

Rotor Spinning Machine R 40



New Spinning Elements R 40


• Position of spinbox allowsoptimized take-off angle

• Increased false twist effectimproves spinning stability

• Improved spinning stabilityallows higher delivery speed

Increased Productivity by optimized Spinning Geometry



Savings per machine and year

Basis: US$ 12,-- per working hour

Ne 7 Ne 14 Ne 30Ne 20

8'000

6'000

4'000

2'000

US$

10'00018½” vs. 16”18½” vs. 17½”

Cost Savings with large Cans (18 ½” versus 16”)



Large Packages, Sliver Cans and Wax Blocks



• Highly modular robot structure

• Fastest piecing and doffingcycles

• Best overview and easysetting with new display

• Easy maintenance ofelectronically controlled electricand pneumatic devices

• Fast startup after machine stop,especially with 4 robots

Trendsetting AERObotic Technology



• Machine lengthup to 320 spinning positions

• Rotor speedup to 150’000 rpm

• Delivery speedup to 255 m/min

• Long machines with up to4 robots for coarse yarns

• Draft up to 400fold

Maximum Productivity with the longest Machine



15% reduced belt pressure decreases power consumption by 10%

Tangential beltRotor

TWINdisc TWINdisc

- 15% - 15%

Energy Savings by reduced Pressure on tangential Belt



• Highly efficient new fan

• 30% less installed powerversus competition

New Energy Saving Generation of negative Pressure



- Basis for profitable Rotor Spinning

• Best yarn quality

• Precise AEROboticautomation

• Optimized spinninggeometry

• VARIOdraft + rotor drive

• Most productive machineof the world

• Low energy consumption

- 15%

Conclusion: Rotor Spinning Machine R 40



Rotor Yarn Processes at > 125 kg/hr (275 lbs/hr)

Yar

n r

equ

irem

ents

Rieter Rotor System

C 60 SB-D 15 (4 cans) RSB-D 35 (6 cans) R 40

C 60 with SB-module RSB-D 35 (6 cans) R 40

C 60 RSB-D 35 (4 cans) R 40

C 60 with RSB-module R 40


Rieter Rotor System

Documents

The Perfect Combination – The Rieter Rotor System - …€¦ · · 2013-03-25ICAC 62nd Plenary Meeting Gdansk, Sept. 7-12, 2003 Rieter Textile System Page 1 (7) Speaker: J Bischofberger