Autoconer 338 –Winding Technology.Multi-Optionality,Know-how, Internationality.

Yarn package winding –Key Technology in the textile production process.

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Yarn package winding is the completion of theyarn forming process and the starting point forvarious subsequent processes, from weaving orknitting to textile finishing. This interface functionof winding is what makes the winding process soimportant. In winding, the course is set for highcost-effectiveness in the following stages of thetextile production chain. At the same time, care istaken that the quality of the yarn wound will meetthe demands placed on it by the finished articles.

Schlafhorst – specialist of yarn winding machinesin the world market for over 50 years – concernsitself intensely with these manifold requirementsand develops innovative winding technology tomeet them. Decisive for the universal acceptanceof the Autoconer is the fact, that Schlafhorst in itswork places the focus not narrowly on winding,but, considering winding as an important part andintegral stage of the entire textile productionchain, consistently develops and advances windingtechnology with the requirements of, and benefitsfor, the entire textile production in mind. Textile-technological know-how crucial in this context iselaborated in cooperation with world-leadingpartners in textile machine engineering.

Typical features of the Schlafhorst performanceare: extensive textile- technological expertise, consequent market and customer orientation, earlyrecognition of changes in market conditions andrequirements, and excellent customer advice andtraining service all over the world. These havecontributed to the world-wide success of the Autoconer, from the first to the present generation.

Translating this know-how into intelligent windingmachine technology has made Schlafhorst for decades the innovation leader in the internationalarena. This is true of the Autoconer yarn splicingtechnology with the modular-design splicer systemand of the quality of the Autoconer yarn packagesdue to the innovative FX- series with its efficientmodules Autotense FX, Propack FX, Variopack FXand Ecopack FX. Thanks to its ingenious modularconcept, the Autoconer offers a convincing uni-versality which enables the machine to produceyarn packages optimally suited for any of the tex-tile production processes downstream of winding.

Materials wound on the Autoconer 338.• Cotton• Wool• Polyester• Viscose• PAN• Linen• Blends

• Kevlar• Special fibres• Natural fibre yarns• Manmade fibre yarns• Short-staple yarns• Long-staple yarns

• Ring yarns• Compact yarns• SiroSpun yarns• Hard and soft Core yarns• High-twist yarns• Plied yarns• Fancy (Effect) yarns• OE-Rotor yarns• Mule yarns• Repco yarns

Autoconer yarn packages for the downstream production processes.

• Dyeing

• Assembly winding/Twisting

• Beam warping

• Sectional warping

• Weaving

• Warp Knitting

• Weft Knitting

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Autoconer yarn packages for dyeing.

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In yarn package dyeing, it is important that dye penetration is uniform and level dyeing is ensuredthroughout the package. Success in package dyeingdepends on many factors including material of theyarn, dyes used, method of dyeing, dyeing apparatusor dyeing liquor pump. What determines the result,however, is the even build and structure of the cross-wound package to be dyed. Thanks to the intelligentcontrol and regulation systems and winding compo-nents of the Autoconer 338, yarn packages can made to suit the requirements of package dyeingexactly. The known dyer's adage saying "Well woundis half dyed" is a measure of the importance of well-structured yarn packages for dyeing, and of theenormous worth of the Schlafhorst winding techno-logy and contribution in this field.The required yarn density of dye-packages varies according to dyeing machine, method of dyeing andmaterial. Package density in winding is directly influ-enced by the parameter “yarn tension”. Thanks toAutotense FX, the desired package density can beobtained with precision, as the yarn tension is set atthe Informator as an absolute value. The constant level of yarn tension ensured by Autotense FX andthe elimination of critical pattern winds on the pack-age through Propack FX are a guarantee for the production of Autoconer packages with an extremelyuniform yarn structure and yarn density. Reproducibleuniformity of the package density from package topackage is ensured by centralised setting of the wind-ing parameters at the Informator. A further factorcontributing to the optimisation of the structure ofdye packages is the lateral yarn layer displacementon the package, achieved by traverse motion of theyarn-guide drum. The regulation of the yarn tensionby Autotense FX has the additional advantage of increasing the average winding speed, which meanshigher productivity in the winding of dye packageson the Autoconer 338.Whirling the yarn ends for fibre entangling in thesplicing process to achieve spliced joints that are simi-lar to the yarn is also beneficial for ensuring that inyarn dyeing the short spliced joints have the samedyeing property as the yarn, so that visible off-shadespots in the fabric are avoided.

Specially for package dyeing of elastic Core yarnsand other elastic yarns, where homogeneous dyeingis critical because of bulging-out package flanks oruncontrollable breakdown of the package structure,Schlafhorst offers as a practicable solution the closed-loop control system Variopack FX. This systemcoordinates the parameters yarn tension and packagecontact pressure throughout the build-up of thepackage, so that well-structured packages with gooddimensional stability are produced.Yarn packages produced on the Autoconer 338 aredyed with excellent results, colouring throughout thepackage and from package to package is absolutelyeven and the results are reproducible. Thanks to the optimal package structure achieved with Pro-pack FX – an essential factor for cost-effective pro-cessing in the production stages downstream of winding – rewinding of the packages after dyeing foruse in subsequent production processes can be dis-pensed with and, depending on the material of theyarn, the Autoconer packages can be used directlyfor the warp or the weft.

Dye package density as a function of yarn tension.

Package density [g/cm3] 0.30 0.33 0.36 0.38 0.40Package contact pressure S S S S S

Autotense FX [cN] 8 14 21 25 30Autospeed 75% 60% 60% 60% without

Winding speed [m/min] 1,200 1,400 1,400 1,400 1,400

Average winding speed [m/min] 890 1,100 1,220 1,275 1,380

Material 100% CO, carded

Yarn count 20 tex (Ne 30, Nm 50)

Drum type 2-pitch sym.

Package format 6”, cylindrical (220 mm)

Wound with lateral yarn layer displacement

Yarn count 42 tex (Ne 14, Nm 24)

Material PES/CV (50/50); 892 T/m

Yarn guide drum, package format 2-pitch asym. 4°20

Yarn tension Autotense FX 15cN (with Autospeed 50%)

Setpoint length 45,000 m

Batch

Pack

age

dens

ity

Even package density.20 winding positions.

Targeted generation of the package density by yarn tension adjustment.

Greatest evenness of package density.

+1.0%+0.5%+– 0%–0.5%–1.0%

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Autoconer packages for Twisting and Assembly Winding.

The Twisting, process places extremely high andquite specific demands on the unwinding pro-perties of the cross-wound yarn packages. This istrue of the twisting process itself and of assemblywinding, a process which in certain cases precedestwisting. In both processes, 2 yarn packages areused for feeding the machines and have to be unwound with equal yarn tension.

Thanks to the Autotense FX Yarn Tension Regulat-ing System, the Autoconer 338 produces yarnpackages with extremely uniform structure anddensity. Central setting of the winding parametersensures reproducibility of the winding parametersfor all packages. There are no variations in yarntension when the packages are unwound in twisting or assembly winding. The plied yarns have an absolutely even structure.

The Length Measuring and Full Diameter Compu-tation System of the Autoconer 338 ensures thatthe length of the yarn in the packages producedis exactly measured and the length is the same inall packages or the packages are all of the samediameter. This is a further precondition for theeconomical production of high-quality plied yarns.High-precision yarn length measuring is possiblewith the Ecopack FX system (optional extra).

Not infrequently, plied yarns have to be producedof wool or elastic single yarns. Up to now, yarnpackages of such yarns could not be fed directlyto two-for-one twisting machines, as placing thepackages on top of one another in the supply creel was impossible because of the bulge-out ofthe package flanks. This problem has been solvedwith the integrated Variopack FX system on theSchlafhorst Autoconer. Bulging-out of he packageflanks is reduced to a minimum. Yarn packagesproduced with Variopack FX can without problembe directly fed to two-for-one twisting machines.

The Autoconer 338 produces packages with allthe formats used in twisting, with a yarn-guidetraverse from 4" to 6". Regular and orderly layingof the yarn onto the package is ensured by thevarious types of yarn guide drums. For windingwool or wool blend yarns intended for twisting,the use of the Thermosplicer is recommended.>2

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Whether for direct feeding to twisting machinesor for feeding to assembly winders, the Autoconeryarn packages offer ideal conditions for cost efficient processing and top-quality results in thetextile production chain.

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Autoconer packages for Warping and Weaving.

In sectional and beam warping as well as weaving,good unwinding performance of the packages forsmooth unwinding of the yarn is decisive for theachievement of high quality and cost-efficiency.Packages must allow highest weft insertion speedsand cope with the enormous alternating stressesdue to changing acceleration on the weaving machine. Processing a multitude of packages simultaneously in sectional and beam warping requires extreme uniformity of the yarn lengths inthe packages from which the yarn is taken. Stop-pages due to yarn breaks or entangled yarns oryarn layers, or other faults disturbing the warpingor weaving process, cause enormous productionlosses. This is why the packages for use in the pro-duction phases downstream of winding are requiredto satisfy the following criteria: absolutely uniformstructure and density with large package diameters,orderly laying of the yarn, safe yarn-like splicedjoints and precisely measured equal length of theyarn on all packages used in a process.Thanks to the expertise in winding technology ofSchlafhorst, the Autoconer 338 is optimally equipped for the production of packages satisfy-ing all these requirements. The Autotense FX YarnTension Regulating System ensures a constant level of yarn tension, and hence, uniform packagestructure and density. The Propack FX Package Cradle Anti-patterning System improves the pack-age structure still further by eliminating criticalpatterning zones.Even at the highest weft insertion speeds, as onair-jet weaving machines, there is no sloughing-offof yarn layers. Thanks to Propack FX, the packagediameters are not limited by critical patterning zoneson the package. The yarn is safely and orderly laidonto the package, even when yarns with critical,smooth structures are wound, due to the smoothstart-up and acceleration of the package and precise guiding of the yarn through the yarn-guidedrum grooves.The modular splicer system of the Autoconer 338offers splicing options for efficiently splicing all typesof materials and producing spliced joints that

safely withstand the alternating stresses to whichthe yarn is subjected on the weaving machine. In the doffing process, the doffer places the yarnbottom reserve onto the package tube and laysthe tip tail onto the package, so that the transferof the yarn from one package to the next in weav-ing presents no problem. The operators can fastenthe yarn ends of the packages together easily andsafely. Highest-precision yarn length measuringwith the Ecopack system guarantees that in warping all the packages on the warping creel runout at the same time, thus reducing the amountof waste yarn significantly.In warping and in weaving, these performancecharacteristics of the Autoconer 338 are a guaran-tee for highest levels of cost-efficiency and pro-ductivity.

Autoconer packages for Knitting.

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In the knitting process, due to the heavy deflec-tion of the yarn by the needles within a narrowspace, the yarn is subjected to exceptionally highstresses. Optimal waxing of the yarn in windingminimises friction of the yarn on the needles anddeflecting elements. The stress on yarn and nee-dles in loop formation is significantly reduced.

The profound textile-technological know-how ofSchlafhorst is also evident in the field of yarn wax-ing. Extensive tests prove that there is a close in-terrelation between yarn tension and the amountof wax rubbed off the wax roll. The intensity ofwaxing must be optimised for every type of yarnmaterial. Each material has its specific optimal lowfriction value only within a narrow zone of thewaxing curve.As it is possible on the Autoconer 338 with its automatic yarn tension regulating system to enterthe yarn tension centrally at the Informator as anabsolute value, the optimal yarn tension can bespecified for whatever yarn is wound. The amountof yarn taken off the wax roll and applied to theyarn is small. Underwaxing and overwaxing is thusavoided.

Yet another important advantage of Autotense FXis, that the amount of wax applied to the yarn iseven throughout the formation of the yarn package,due to the fact that Autotense FX holds the yarntension constant within the spinning bobbin unwound and from spinning bobbin to spinningbobbin.The wax roll monitoring feature integrated intothe waxing device ensures that no unwaxed yarncan be placed on the cross-wound package. A signal calls the attention of the operator well in time before the wax roll runs out. >1

For knitters, Autoconer yarn packages offer theadded advantage of excellent unwinding perfor-mance on the knitting machines: tapered packageswith up to 5°57 taper, if required with increasingtaper to 11°, and with large diameters. The bottomyarn reserve and the tip tail of the package, formedby the package doffer, are essential for easy hand-ling and safe yarn transfer at the package changeon the knitting machine. The yarn-like splicedjoints produced by the Autoconer are resistant tofibre shifting at the deflection points in the knit-ting machine.

Trouble-free work with the Autoconer packages inthe textile production processes translates intohigh efficiency rates of the equipment and superiorquality of the knitted fabrics.

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Targeted yarn waxing through yarn tension variation.

Yarn

fric

tion

coef

ficie

nt µ

Interrelation of Yarn Tension [cN] and Yarn Friction Coefficient µ.

0.25

0.20

0.15

0.10

0.05

0.00

15 cN 20 cN 25 cN 30 cN 35 cN 40 cN 45 cN

Minimum quantity of waxrubbed off the wax roll

0.96g wax/kg yarn.

Yarn material 20tex (Nm 50/1; Ne 30/1) 100% CO, carded

Winding speed 1,200 m/min

Type of wax Reseda Binder green

Yarn tension see diagram

Yarn tension [cN]

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Up-to-date yarn structures –Optimal winding on the Autoconer 338.

Compact yarns.In the winding of Compact Yarns, the main require-ments placed on the winding process are main-taining the specific properties and quality of theyarn, also in yarn splicing, and the production ofoptimally-structured cross-wound packages fortrouble-free unwinding and careful handling ofthe yarn in the production processes subsequentto winding. The focus of the adapted windingtechnology is also on maximised resource utilisa-tion and online process and quality monitoring.The unique upper-yarn sensor and the suction system with controlled operating vacuum of theAutoconer 338 ensure gentle treatment of theyarn in package winding. Careful handling of thepackage surfaces and a minimum amount of yarnwaste are ensured by the low vacuum level, whichcan be set to suit the specific characteristics of theyarn wound, and the short upper-yarn search andsuck-up times. There is no roughening-up of theyarn by excessive intensity of the sucking action.

Autotense FX and Propack FX ensure uniformstructure of the packages with the least possiblestress on the yarn. Their action is supported bythe package lift-off motion at a yarn break orclearer cut, yarn guide drum and package beingbraked to a standstill separately from one another,and by the direct, sensor-monitored yarn pathwith only slight deviations.As required for the application, the Autoconer cansplice Compact Yarns either with the Standard-splicer or the Injectionsplicer. The Thermosplicer isavailable for the splicing of Compact Yarns ofwool. With these options, the highest demandson strength and appearance of the spliced jointscan be efficiently met.The Ring Spindle Identification System in Auto-coner-RSM linked installations extends online quality control on the Autoconer right back to thering spinning machine. Yarn faults originating inthe ring spindles can be pinpointed and eliminatedat a very early stage. Constant and consistentlyhigh yarn quality is thus ensured. The optional

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central Conerpilot data acquisition system supportsonline quality monitoring.The modular architecture of the Autoconer wind-ing technology for adaptation to any applicationallows efficient, cost-effective winding of all short-staple and long-staple Compact Yarns spun in themarket.

Elastic Core yarns.The specific structure and great diversity of thematerial of which elastic Core yarns are made places very high demands on yarn winding, inparticular on the splicing technology, structureand build of the yarn packages and process reliability. For the winding of elastic Core yarns,Schlafhorst offers an optimised winding processspecially adapted to the requirements of elasticCore yarn winding.The package format is optimized by Autotense FX,Propack FX and, in particular measure, by Vario-pack FX. To reduce bulging-out of the packageflanks to a minimum, Variopack FX coordinatesyarn tension and package contact pressurethroughout the build-up of the package in such away that dimensional stability of the package isensured.

For the splicing of elastic Core yarns, Schlafhorstoffers the Elastosplicer, which, through its speciallyadapted yarn geometry, additional braking ele-ments and precisely timed operating cycles, pro-duces Core-yarn spliced joints of convincing quali-ty. The splices stand out by their excellent visualappearance, great strength and high resistance toalternating stresses.

Software and sensor technology in the Autoconer338 guarantee reliable, well-coordinated controlsequences. The winding process can be optimisedin such a way that the very best conditions arecreated, whatever the specific properties of theyarn wound are. This is one of the strong pointsof the Autoconer 338 in the continuation of theAutoconer success story.

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Schlafhorst

Zweigniederlassung der

Saurer GmbH & Co. KG

Blumenberger Str. 143-145

D-41061 Mönchengladbach

Phone +49 2161 28 0

Fax +49 2161 28 26 45

info@schlafhorst.de

www.schlafhorst.de

P-W-207-01/05, ka, e