Twisting : Wasteful Power N Killer Sound

TFO Twisting is relatively new Technology. However, when it comes to the Machine Design, it is questionable.

First Twist : Between the Twist Tube and the Moving Spindle.

Second Twist : Between the package and the Moving Spindle .

In both the twist, the Moving Spindle is the Control Point. Higher the Speed of the spindle, more the production.

But, then Industry has found that beyond a certain speed threshold, the power consumption does not go up linearly, but geomaterically. So, here is a technology, which has inherent PPF limitations ( For PPF, read my post on Quality )

As long as the power cost are lower, this issue is not a limiting factor, however, as soon as the power cost does not justify the incremental benefit of productivity, the machine does not pass the Viability Threshold.

Machine makers did move recently in the direction of making smaller pot diameters to battle the high energy cost. But no sooner you go to a smaller pot diameter, the PPF of the Twisted Package reduces as the output is Knotted yarn, which the subsequent user does not want.

The machine makers did not see that the solution was in simply making 8 inches and 10 inches feed packages.

A 8 inches feed package machine will automatically give a 1.86 kg package without knot on a rather smaller spindle diameter, then a 6 inches package. And if it is 10 inches, then the spindle becomes far more smaller.

While Volkmann and Murata, both made smaller and smaller pot size and as low as 90mm, but not gone into designing a larger feed package simultaneously to make it a superior machine.

The argument given is that this will give a larger balloon and hence the power consumption advantage will get nullified. However, as per field experiments carried out by me ( We designed a 8 inches package and fed to a smaller pot dia, of only 135 mm and came up with a 1.86 kg package without knot) and we found that actually, the speeds could be taken up to 14,000 rpm with a productivity increase of 17% from a speed of 12,000 rpm and with no increase in power consumption. Plus the bonus of increase in efficiency in Assembly Winder.

Therefore, if One Knot is acceptable limits, then a pot dia of only 70mm is enough to take the speeds upto 20,000 rpm and bring in a productivity gain of around 100%. Buy the technology of hairiness control from me.

Though Volkmann does offer 8 inches feed package, but has never been able to successfully pitch it to the customers, on account of lack of facts and figures.

Further, why not have the balloon enclosed in a vacuumed environment to keep the balloon drag lowest.

Unfortunately, no work has been done in this direction. But general common sense would say, if you were to enclose the spindle in a vacuumed area, the air drag should be practically zero. Which would mean, enclose the spindle right till the balloon breaker guide and with a vacuum pump keep pulling the air out.

I have no experience with it, but can still say, that the balloon drag will significantly reduce and the power consumption drop.

Second.

The times of running spindles with Belt is over. Each spindle needs a simple motor drive directly coupled to the spindle. ( There are now motors avl to run at speeds of 100,000 rpm)

Third :

The take up does not need cams anymore. For a straight simple package, there are enough reversible motors available.

Fourth

The deafening sound of the machine can be better avoided by keeping the headstock outside the department and the main machine inside the department. ( Though, if individual motors are installed, this sound thing is naturally taken care). A good engineer will , however, also keep the Belt running below the floor level and cover the service area with a checker plate. The whole issue of Machine sound is covered. But only if the machine makers themselves have seriousness to advise the client for such simple solutions.

Fifth

Machines have to be Double Decker. Floor space is becoming very expensive and more and more mills have no room for expansion. This also permits more spindles being covered by the same operator,

Sixth

If power is such a major issue in Twisting, then why not provide on the panel a power meter. It cost now only Euro 100, but is a significant tool in the hands of the management to take the productivity up .

Seventh

Technology has to move further to Four For One Twisting. A Turkish Twisting machine maker has gone in to turn the take up drum and insert two twist. This gives a direct opportunity to make Four For One Twister. Two twist coming from the tail of the twister and two coming from the head of the twister.

Well, the biggest drag in innovation is sometimes the user himself. The user goes largely by Industry perceptions and less by his own experience. Unless and untill the user is ready to challenge the STATE OF BEING AND INNOVATE, most machine makers themselves cannot bring about any improvement.