Package formation

Package geometry
• Bobbin has cylindrical body with
tapered ends

Height (H) = 12 to 16 inch

Diameter( dB) = 5.5 to 6.5 inch

Taper angle ( α ) = 80 to 95 degree

• Typical bobbin size:
• 12.5 inch x 5.5 inch
• 12.0 inch X 6.0 inch
• 14.0 inch x 6.5 inch
• 16.0 inch x 6.0 inch
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 d

D H

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 Bobbin formation
• Roving is wound in the form of coils adjacent to
each other on bare bobbin surface from
bottom to top end

• The coils neither should overlap nor leave too

much space between them

• The length of bobbin surface filled with roving

is reduced to create a taper end
Layers

• Too high taper angle ( α ) may cause roving

Roving bobbin
coils to slip

• Too low taper angle reduces roving content

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 Winding possibilities
1. Either bobbin Or presser rotating
𝑃2

Roving wound
𝐵2
Bobbin 𝑃1 Roving wound
𝐵1 𝑃1 𝐵1
Presser
Bobbin 𝑃1
𝐵1 𝑃1 𝐵1
𝑡=0 𝑡 = 𝑡1 Presser

Bobbin stationery & presser moving 𝑡=0 𝑡 = 𝑡1

𝑛𝐵 = 0, 𝑛𝐹 > 0
Bobbin moving & presser stationery
𝑛𝐵 > 0, 𝑛𝐹 = 0

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 2. Bobbin & Flyer rotating in the same direction

𝐵2 Roving wound

𝑃2
Bobbin 𝑃1 𝑃2
𝐵1 𝑃1 𝐵1
Presser
Roving wound
𝑡=0 𝑡 = 𝑡1 𝐵2
Bobbin 𝑃1
𝐵1 𝑃1
𝐵1 Presser
Bobbin & presser both moving in same direction
𝑛𝐵 > 𝑛𝐹 > 0
𝑡=0 𝑡 = 𝑡1
Bobbin & presser both moving in same direction
𝑛𝐹 > 𝑛𝐵 > 0

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3. Bobbin & presser moving in opposite directions

𝐵2
Bobbin 𝑃1
𝐵1 𝑃1
𝐵1 Presser

𝑡=0 Roving wound

𝑡 = 𝑡1 𝑃2

Bobbin & presser both moving in opposite directions

𝑛𝐹 ≠ 𝑛𝐵

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Advantages of bobbin leading frame
• The motion transmission path from motor to spindle is shorter than bobbin. So
the spindle / flyer start early and the bobbin when the machine is switched on.
The bobbin starts with some delay. There fore for flyer leading frame , the roving
will tear near the presser. Hence bobbin leading is better.

• Once the roving breaks , unwinding of layers will start with leading spindle/ flyer
because the roving will move against air resistance. This will not happen if it is
flyer leading.

• With a leading bobbin, the bobbin speed must be reduced slowly with increasing
bobbin diameter, i.e. with increasing mass to be moved. This is advantageous in
terms of power consumption. On the other hand, with a leading spindle, the
bobbin speed must gradually be increased.

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 Roving sloughing -off

Bobbin Bobbin
Broken roving
Presser end
Roving
Air resistance Roving
Presser
Broken roving end
Bobbin leading
Flyer leading

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Winding equation
𝑛𝐹
𝑇𝑤𝑖𝑠𝑡: 𝑇 = ……..(1)
𝑣
𝐷𝑒𝑙𝑖𝑣𝑒𝑟𝑦 𝑟𝑎𝑡𝑒 = 𝑊𝑖𝑛𝑑𝑖𝑛𝑔 𝑟𝑎𝑡𝑒
𝑊𝑖𝑛𝑑𝑖𝑛𝑔 𝑟𝑎𝑡𝑒 = 𝑊𝑖𝑛𝑑𝑖𝑛𝑔 𝑠𝑝𝑒𝑒𝑑 × 𝐵𝑜𝑏𝑏𝑖𝑛 𝑑𝑖𝑎𝑚𝑡𝑒𝑟 × 𝜋
= 𝑟𝑒𝑎𝑙𝑡𝑖𝑣𝑒 𝑠𝑝𝑒𝑒𝑑 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑏𝑜𝑏𝑏𝑖𝑛 𝑎𝑛𝑑 𝑓𝑙𝑦𝑒𝑟 × 𝑏𝑜𝑏𝑏𝑖𝑛 𝑑𝑖𝑎𝑚𝑡𝑒𝑟 × 𝜋

= 𝜋𝑑𝐵 ( 𝑛𝐵 − 𝑛𝐹

𝑣 = 𝜋𝑑𝐵 ( 𝑛𝐵 − 𝑛𝐹 …….(2)
Delivery rate : 𝑣 (constant)
𝑉
Twist : T ( constant) 𝑛𝐵 = + 𝑛𝐹 ………(3)
𝜋𝑑𝐵
Flyer speed : 𝑛𝐹 ( constant) 1
(𝑛𝐵 − 𝑛𝐹 ∝ ………… (4)
Bobbin speed : 𝑛𝐵 ( variable) 𝑑𝐵
Bobbin diameter : 𝑑𝐵 ( Variable)
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Operations for bobbin building

1. Reduction in bobbin speed with increase in bobbin diameter

2. Change of traverse rate of bobbin rail

3. Change in direction of traverse at the end of upward &

downward journey of bobbin rail

4. Shortening of traverse length with each layer formation

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 Traverse rate of bobbin rail
𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑐𝑜𝑖𝑙 = 𝜋𝑑𝐵
Length of roving delivered / min = v
𝑣
𝑁𝑜. 𝑜𝑓 𝑐𝑜𝑖𝑙𝑠 𝑡𝑜 𝑏𝑒 𝑤𝑜𝑢𝑚𝑑 𝑝𝑒𝑟 𝑚𝑖𝑛 =
𝜋𝑑𝐵

Flyer is stationery and the bobbin rail moves up & down

Distance to be moved by bobbin rail per min:

𝑣
= × 𝑑𝑅 bobbin
𝜋𝑑𝐵
Roving
𝑣 𝑑𝑅
Traverse rate of bobbin rail (VBR): 𝑉𝐵𝑅 = × 𝑑𝑅 𝑑𝐵
𝜋𝑑𝐵

1
𝑉𝐵𝑅 ∝ Roving diameter = dR
𝑑𝐵

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Change in direction of traverse

• To create conical bottom and

top part of the bobbin
• Traverse direction has to be
changed both at the bottom and
top of the bobbin

• Traverse length has to be

shortened.

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Variable drive
• Bobbin speed needs to be changed ( reduced)
as bobbin diameter increases
• It is achieved by using a pair of cone drums and
shifting the belt along its length by an
predetermined amount depending upon the
layer thickness

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 Bobbin drive Differential
gear Top cone drum

• Flyer rotational speed ( nF) is kept

constant as we have to keep the twist
constant
• For a given layer formation, bobbin
diameter ( 𝑑𝐵 ) remain constant Source of
• Hence, bobbin speed has to be held Bobbin Variable speed
constant as long as a particular layer is
being formed
• For each layer formation , the bobbin Bottom cone drum
diameter increases. Hence, bobbin speed 𝑉
(𝑛𝐵 ) has to reduce with layer formation. 𝑛𝐵 = + 𝑛𝐹 ………(3)
𝜋𝑑𝐵
• Change in bobbin speed is brought about 1
by using variable drive ( cone drums) (𝑛𝐵 − 𝑛𝐹 ∝ ………… (4)
𝑑𝐵
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 Designing Cone drum profile
• At end A , the radius of driven cone is smaller than Driver
the driver cone A
B
• At the end B the opposite is true 𝑟1
𝑛1
• The two cones must satisfy the following two x
conditions:
Belt l

1. Since motion transmission is by a common belt on the

drums , the radii of the two cones at any location should be 𝑟2
such that the length of the belt required at any position 𝑛2
remains constant Driven
y

2. The rate of change of speed ratio of the pulleys with

position of the belt must satisfy some condition imposed by
the purpose for which the variable speed mechanism is
required.

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 Driver
Condition 2: A
B
The cones must be so shaped that while the belt moves a distance 𝑟1
y cm ( length of the drums) parallel to the axis of the drums, the x 𝑛1
speed of the driven cone varies linearly from 50 to 200 rpm while
the speed of the driver pulley being 100 rpm. Belt l

𝑟2
𝑛2
Roving hank Driven
1.0 Ne y
1.4 Ne
Bobbin diameter

1.8 Ne

The bobbin diameter increase linearly with successive

roving layer formation assuming constant roving
diameter through out roving build .

0 4 8 12 … 48
Layer number
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 Since the drums are far apart , it may be assumed that
the angle of wrap around the cones is same and
equals to 1800. Driver
A
B
𝑟1
So the length of belt = 2𝑙 + 𝜋 𝑟1 + 𝑟2 𝑛1
x

l = Distance between the shaft ( constant) Belt l

r1 & r2 = Radius of the two cones at any given position
of the belt 𝑟2
𝑛2
Driven
y
Since l is constant,

𝑆 = 𝑟1 + 𝑟2 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 … . . (1

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 Driver
At any location of belt A
B
𝑛1 𝑟1 = 𝑛2 𝑟2 𝑟1

x 𝑛1
𝑛1 𝑟1 𝑟1
𝑛2 = = 𝑛1 × = 𝑛1 𝑅 … (2
𝑟2 𝑟2 Belt l

𝑛2 varies linearly with ratio R 𝑟2

𝑛2
Driven
y
Control requirement
The top cone drum speed (n1) = 100 rpm

Bottom cone drum speed ‘𝑛2 ’ has to vary from 50 rpm to 200 rpm as the
distance (x) of the belt from point B varies from 0 to y cm.

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For constant n1, n2 depends upon the radius ratio R. 2.0

Thus, to satisfy the speed requirement , R has to

change from 0.5 to 2.0 as x changes from 0 to y R

0.5
Hence,
𝑥 0
𝑅= 0.5 + 1.5 ……… (3) x Y
𝑦

𝑟1 = 𝑆 − 𝑟2 … . (4

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Substituting r2 in equation (3)
𝑟1 S − r2 𝑥
𝑅= = = 0.5 + 1.5
𝑟2 r2 𝑦

S 𝑥
− 1 = 0.5 + 1.5
r2 𝑦

S 𝑥 x
= 1.5 + 1.5 = 𝟏. 5 1 +
r2 𝑦 y

S S×y
∴ r2 = = … … … (𝟓
x 1.5 (x + y
1.5 1 +
y

Substituting r2 in equation 4 , r1 can be found out.

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How much should be cone drum length Y?
• Let the roving diameter = dR= 1.0mm
• Diameter in compressed state= k dR = 1.0mm ( assuming k=1)
• Bare bobbin diameter = 5cm
• Full bobbin diameter = 15 cm
15−5
• Layer thickness = = 5.0cm
2
50.0
• Number of Layers = = 50
1.0

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Determination of Cone drum length…….
• The belt shift per layer formation should not be too close or too
wide. Keeping in mind the limitation of shifting mechanism which is
purely mechanical and it is kept around 12mm

• No of shifts = number of layers = 50

• Total shifting of belt = 50x12= 600mm
• Some part of the cone drum has to be left unused on both sides of
cone drum so that the belt does not slip from the edges. It could be
75 mm
• Total length = 75+75 + 600 = 750mm
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 Hyperbolic Cone VS straight surface cone
Hyperbolic cones

• Hyperbolic cones are difficult to design

Hyperbolic cone
• Belt has to move on surfaces of varying inclination
• Belt is shifted by constant amount

Straight cone
• Straight sided cones are easy to design
• The belt must be shifted in steps of varying
magnitude. Initial steps are to be large and later on
to be smaller.
Straight cone
• An eccentric used for belt shifting
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 Differential drive
𝐴 𝐷 32 15 10
𝑒= × =+ × =+
𝐶 𝐵 16 33 11
15T 16T
45T
D C V

Let the central shaft speed = 705 rpm

B A
33T 32T No input from cone drum i.e.
From driven speed of gear v = 0
cone drum output gear( gear B) speed= l
first gear ( Gear A) speed= f
37T speed of arm i.e. casing = a
32T
45T

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Bobbin speed calculation
15T 16T
45T
𝑙−𝑎 D C
𝑒=
𝑓−𝑎
10 𝑙−0
+ = B A
11 750−0 32T
33T
10 From driven
𝑙 = 705 × cone drum
11

• Speed of gear B and 45T are same as 705 rpm

they are mounted on shame shaft. 37T

32T
• Speed of bobbin 45T

10 45 45
= 705 × × × = 1000 𝑟𝑝𝑚
11 32 37
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 Belt shifting Driver cone

mechanism
Wire Dead
• A ratchet wheel control the belt Ratchet
Belt
weight
shift mounted on axle 20. guide

• The ratchet wheel moves by half Driven Cone

tooth after each changeover of
operation.

• By gear train , change wheel and

eccentric , the ratchet releases
the wire rope and enables the
belt guide to move to the right.
The force required for movement
is exerted by the dead weight
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• By gear train , change wheel and
eccentric , the ratchet releases the
wire rope and enables the belt
guide to move to the right. The
force required for movement is
exerted by the dead weight.

The rate of increase in bobbin diameter depends upon roving thickness

i.e. roving hank. The belt must be shifted by corresponding steps. The
amount shift is regulated by replacement of ratchet wheel or by change
gear . Ratchet with fewer teeth means larger steps or vice versa.

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 Bobbin rail movement
Lifter motion
with rack
Requirement
• Bobbin rail keeps traversing up & down
• Each coil must be placed adjacent to each
other
• Coils should be neither overlap nor leave
gap between them.
• The shifting of laying point is performed by
Lifter motion
moving the bobbin rail which holds the with lever
bobbin.
• Rail is moved either by lever or by rack &
pinion

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Bobbin rail speed(VBR)
• The lifter speed needs to be changed
as bobbin diameter increases
Lever
𝑣
𝑉𝐵𝑅 = × 𝑑𝑅
𝜋𝑑𝐵

• Motion to bobbin rail must be fed

from variable source i.e. from bottom Driven cone
cone drum drum

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End

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