Polar E Premium

Polar E Premium
Automatic winder
1
Polar E Premium
A big step forward
It is indeed recognized that the maximum level of
automation on the winding process, is achieved by a direct
link of the ring spinning frames to the winder.
The advantages, already well known, through the
continuous automatic transfer of the ring bobbins from
one machine to the other are:
• yarn quality of the wound package which is preserved
being the bobbins prepared and automatically doffed
on the ring frames, without any operator handling or
loading into separate boxes;
• higher efficiency on winder;
• production output flow consistency and timed, as a
single machine;
• minimization of winding room personnel.
Most of customers select the link system solution
whenever a new mill has to be set, or in alternative,
whenever old ring spinning frames must be substituted.
As a consequence, the real focus of Savio has been
dedicated to propose an alternative solution, for all
other mills where mainly existing ring frames are without
automatic doffing, with the same winding efficiency of the
link solution.
Polar E Premium, has been designed to evenly process
those yarn bobbins, whose formation is not originally
“favourable” to reach that efficiency, keeping also the
minimum number of operators.
2
3
Polar E Premium
Hopper
The capacity has been
increased thanks to the
“double alternate” bobbin
loading system on the peg.
To achieve the full efficient
peg loading rate, bobbins
are mechanically spaced,
bobbin shape identified by
the“profile reader sensor”
and properly oriented by
the “cross shaped” rotating
device.
4
The “profile reader sensor”
detects also the empty tube
and diverts it into a separate
dedicated collecting box.
The enhanced hopper
capacity and efficiency,
allows a loading rate to cover
the winding heads up to 72
spindles.
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Polar E Premium
Peg feeding system
An efficient loading system
requires that:
• the oriented bobbins
before be loaded on the
relevant peg, are cleaned
from any flying attached
yarn by an air suction
located in each of the two
coupling sleeves.
6
7
Polar E Premium
End finder station
Particularly designed to
handle bobbins with yarn
reserve at the bottom
of the tube (ring frames
without automatic doffing),
the end finder station is
provided with a “knife bunch
remover” in combination
with an air suction
blow for the cleaning;
contemporaneously the
yarn tail is introduced into
8
the tube upper hole to get
the bobbin prepared to the
winding head.
All above described features
of the Hopper/Peg feeding
system/End finder station,
transform the original
“manual doffed” bobbin into
a similar one used in the link
system.
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Polar E Premium
End finder station layout
The machine design has
been focused on the lay out
of the end finder station as
follow:
• the end finder stations,
are distributed along
the machine frame and
consequently allow
the proper balanced
distribution feeding
capability to the whole
machine. The machine
can be regarded as
a coupling of 2 o 3
single machines; the
“centralized end finder
system” cannot permit
same even balancing.
10
With this “balanced”
solution, Polar E Premium
can have up to max. n° 72
winding heads.
Their positions being placed
separately from the main
bobbin/pegs belts flow, do
not affect at all the efficiency
of the system.
Being front-side located,
allow an easy intervention of
the operator.
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Polar E Premium
Back up station
A great help to ensure the
highest efficiency of the
winding process is given by
the “Back up station” which
shall take care of all bobbins
rejected by the winding
heads for different reasons:
• Bad shaped bobbins.
• Bobbin with yarn
remnants.
• Bobbins with
technological alarms
(off-standard quality yarn
values).
12
The station is able to prepare
again the bobbin, with an
high efficiency rate, because
of the slow moving speed,
and or to remove the faulty
yarn portion, in case of a
technological alarm.
The diversified and specific
movements are possible
thanks to the “identification
system” embedded on the
machine and peg.
The end result is also
significant in terms of
operator reduction, since no
intervention is requested to
the personnel.
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Polar E Premium
Intelligent bobbin distribution
Fresh bobbins
BOBBIN LOADER
1
A traffic regulation is
necessary for long machines;
at this purpose identification
tags placed in the peg trays
allow:
• automatic balancing
of feeding flow rate to
yarn end finders: all
the machine section
and winding heads are
equally fed and avoid idle
spindles;
• traffic jams are also
avoided;
• technological alarms are
automatically removed;
• reduction of operator
intervention.
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2
2
3
Bobbins prepared
for winding
process
Tube with
remnant yarns
Empty tubes
WINDING SPINDLES
4
5
Unrecoverable
bobbin
Yarn finders
rejected bobbins
Spindles rejected
bobbins
Technological
alarm
HEADSTOCK
5
1Hopper
2 Bobbing loading system (L stations)
3 Tube clean station
4 Back up station
5 End finder station (YF)
• Fresh bobbin are loaded
on L stations and
conveyed to YF1, YF2,
YF3.
• Rejected bobbins, tubes,
technological alarms are
discharged on the return
belt.
• Tube with remnant yarns
are cleaned by the tube
cleaner and reinserted in
the circuit.
• Rejected bobbins and
technological alarms are
conveyed to Back up
station and reinserted in
the circuit.
• Unrecoverable bobbins
are parked on standby
belt.
• Empty tubes are collected
in a dedicated box. Also
remnant bobbins and
unrecoverable bobbin can
be conveyed in separated
boxes.
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Polar E Premium
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Polar E Premium
Flexible cycle
1
2
1
3
2
PC
4
5
4
3
1 Independent movement of the package
yarn suction nozzle
2 Independent movement of the splicer
3 Independent movement of the bobbin
yarn suction nozze
4 Independent movement of the yarn
tensioner device
Flexible cycle
Thanks to the individual
motors and PC, the splicing
cycle is automatically made,
as per the actual requests of
the splicing steps, improving,
as consequence, the
efficiency and production of
the winder.
Consequently:
• Greater productivity
• Consistent package quality
(no presence of double
yarns or yarn scrambling)
• Power and compressed
air savings because
unnecessary splicing cycle
are avoided
• Minimum wear of the parts
• Minimum yarn waste
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1Drum
2Traverse
3 Tension sensor TENSOR
4 Waxing device
5 Yarn tensioner
Computer Aided Tension
The winding tension is
detected continuously by the
Tensor, which interacts with
the yarn tensioner device,
through the machine PC, in
order to adjust the load on
the yarn as required. The
Tensor, being positioned just
before the drum detects on
line the real winding tension.
The sensor does not have any
movable parts and performs
as “antiwrap system”.
Tensorflex (standard)
In presence of elastomeric
yarn blended with wool/cotton
the tension values must be
diversified during the package
formation to ensure a perfect
shape.
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Polar E Premium
Anti patterning system
1
1
4
2
2
4
3
3
20
1 Drum speed
2 Package holder position
3 Ratio between package/drum
diameter drive in actual time
4 Ribboning zone
1 Drum speed
2 Package holder position
3 Ratio between package/drum
diameter drive in actual time
4 Ribboning zone
Electronic anti patterning
system
On/Off modulation operates
at critical diameters only.
In the On/Off system, all
the critical rates between
package and drum
diameters are memorized
by the computer and
consequently the drum is
accelerated and decelerated,
according to variable ramps,
when there are possibility of
ribboning formation.
The system operates also
during the acceleration after
the splicing cycle.
Computer Aided Package®
(optional)
It gives a perfect package,
without ribboning and
without changing the drum’s
speed. The computer
checks the distance
between two consecutive
layers and modify the ratio
between package and drum
diameters by micrometric
variation in the inclination
of the package holder and
consequently in the driving
point.
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Polar E Premium
Controlling the winding process
All parameters of the winding
process are controlled by the
Computer:
• yarn quality
• package quality
• production quality
• control of all peripheral
units
• energy consumption.
The Computer has a large
touch screen and printer.
The data are displayed in
a descriptive and graphical
form.
Ethernet interface for
connection to higher level
information systems. The
peripherals’ programme
can be updated directly on
the PC (also with remote
loading).
1
2
3
1
Yarn count alarm
Different count
2
Package off standard
Max n° of splicers in the package
3
Bobbin off standard
Max n° of cleares cut in the bobbin
4
Yarn quality off standard (basic clearer)
Max n° of neps - thin - thick places
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Spindle Monitoring System
Each winding head is
equipped with an alarm
monitoring system.
The operator is notified in
real time of the ongoing
alarm. Each spindle
indicates technological as
well as functional alarm.
4
5
6
7
8
9
10
11
12
5-8
Examples of red ligths due to suction
package/bobbin/clearer splicer
Yarn quality off standard
9
Foreign fiber
10
Count variation
11
Moire
12
Pearl chain
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Polar E Premium
Doffer trolley
• The doffer trolley is
electronically integrated
with the winding heads
and the machine PC.
• All the moving parts
are driven by individual
independent
motors so to reduce the
doffing cycle time to 13,5
seconds.
• The universal clamp
is able to handle a
certain different range
of embty tubes conicity
simultaneously without
parts change.
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Energy saving
• A new designed basket
geometry to store different
tubes conicity with no
parts change, and to
allow the easy tube colour
recognition when different
yarns are processed on
same machine.
• The reserve yarn length is
adjustable by the machine
PC in order to meet any
end user request.
• A fast patrolling speed
up to 60 mt/min. in order
to increase the doffing
efficiency.
• The laser technology
ensures the precise
positioning of the doffer
with the winding heads.
Particular attention has been
given to the suction system
which represents the highest
portion of the energy in the
winding process.
A special fan, with high
performances aerodynamic
blades in addition to the
direct motor drive requests
a minimum consumption of
electric power.
The motor fan, controlled by
the machine PC through an
inverter, adjusts its speed
automatically in accordance
with the actual working
conditions and parameters.
The yarn waste is collected
in a separate filter box
located in the machine
headstock.
The same fan provides also
the vacuum to unload the
travelling blower waste,
once the blower reaches the
proper discharge pipe also
located in the headstock.
The travelling blower waste
is collected in a second
separate filter box.
In case of the “Dust
collection system” device,
the waste is unloaded in a
third separated filter box.
1 Yarn waste filter box
2 Dust removal system filter box
3 Travelling blower filter box
Dust collection system
(optional)
A single suction unit for
each head, located at the
height of the balloon breaker,
captures fibrils and dust
produced when the bobbin
is being unwound. Suction is
created by a fan that serves
two sections of heads. The
impurities and dust are
collected by a filter.
2
1
PC
3
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Polar E Premium
Total splicing system
Air splicer: settings by
machine PC
Air splicer settings are
completely centralised
and consequently
extremely quick and simple
furthermore consistent
uniformity of the yarn
splicers on different winding
heads is guaranteed.
Main application range:
• Cotton 100% and blends
• Cotton Compact yarns
• Fancy yarns
• Core yarns
• Synthetic and artificial
yarns
• Wool 100% an blends
•Silk
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Water splicer Duo Stage
(optional)
To increase the joint strength
even with the compact
yarns, mercerized and
singed yarns, the splicing
operation is made under
vacuum while the water is
injected (Duo-Stage). All the
splicer parts are located in
a “water proof” housing to
avoid dangerous spray of
water outside.
Main application range:
• Cotton 100% coarse counts
(flat and fancy yarns)
• Cotton 100% compact yarns
• Mercerized/singed yarns
• Elastomeric yarns
• Two ply yarns
• Open End yarns
• Synthetic yarns
• Linen yarns
Heat-Splicer
(optional)
The consolidated experience
on the splicer air technology
in combination with the use
of the heat, guarantees a
final joint with excellent
appearance, high and
consistent strength even
with, difficult yarn structures,
different blended materials
and high twisted yarns.
Main application range:
• Carded wool coarse
counts
• Mule spun yarn
• High twist yarns
• Wool 100% and blends
Twinsplicer
(optional)
The way the splice is
prepared and made, ranks
the Twinsplicer at the top
among all other splicing
devices. The splicer strength
is always above 95% and
the appearance same as the
parent yarn. The splicer on
compact yarns, beside the
strength, needs an extremely
good appearance not to
create a visible defect on the
finest fabrics. The Twinsplicer
for core yarns preserves the
elastomeric filament entirely
inside the joints.
Main application range:
• Cotton 100%
• Cotton 100% Effect yarns
• Compact Yarns
• Elastomeric yarns
• Cotton and blends
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Polar E Premium
Computer Aided Density - Computer Aided Metering
PC
2
1
3
1
2
PC
28
1Piston
2 Electronic/p neumatic valve
3Cradle
1 Package and drum speed sensor
2 Laser detector signal
Computer Aided Density
(optional)
• Control of the package
load on the drum.
• The package weight
increase is detected
by the length metering
and consequently the
“electronic/pneumatic
valve” is activated.
• Customized package load
curve.
• The relevant parameters
are programmable and
stored in the machine PC.
The system is especially
studied to process compact
yarn producing soft
packages for Dyeing (0.32 /
0.35 g/cm3).
Computer Aided Metering
(optional)
• The combination of the
laser detector beam
with the package and
drum speed sensor,
is elaborated by the
machine PC software.
• The system allow a
metering high precision
repetitiveness. ± 0,5%.
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Polar E Premium
30
3195 (SM) - 3150 (SBB)
2684
H
35
1135
B
2932
2278
1810
2660 (8T)
2020 (6T)
1600
620
620
1275
MACHINE LENGTH
SM = Savio Magitex - SBB = Savio Belt Blower - E = Electrojet
24
26
28
30
32
34
34
36
38
38
40
42
44
46
48
6T
3
2
1
3
2
6
1
4
3
2
1
3
8T
1
2
3
4
2
3
4
5
2
3
4
5
6
4
mm
15530
16170
16810
17450
18190
18830
18930
19470
20110
20210
20850
21490
22130
22770
23510
24
26
28
30
32
32
34
36
38
40
42
44
46
48
48
50
52
60
64
70
72
6T
2
1
3
2
6
5
4
3
2
1
3
2
6
5
4
6
3
2
8T
2
3
4
2
3
1
2
3
4
5
6
4
5
2
3
4
8
4
7
8
mm
16170
16810
17450
18190
18830
18930
19570
20210
20850
21490
22130
22770
23510
24150
24250
24890
25530
28090
29570
31490
32130
30
34
36
38
40
42
44
46
46
48
50
52
60
64
70
72
6T
6
4
3
2
1
3
2
6
1
4
7
3
1
6
9
Bobbin case
Length
Sections
N. heads
With 3 end finder station
Length
Sections
N. heads
With 2 end finder station
Length
Sections
With 1 end finder station
N. heads
Automatic independent head winding machine, equipped with motors with individual
speed adjustment and a flexible operating cycle.
Models: POLAR E PREMIUM - independent winding machine.
Headstock: right or left with respect to the working front.
Frame: modular frame consisting of 6 or 8 head sections.
Number of heads/machine: from a minimum of 24 to a maximum of 72 (see
installation layout).
Materials: natural, synthetic and blended staple yarns.
Count range: from tex 286 to tex 4, from Ne 2 to Ne 147, from Nm 3.5 to Nm 250.
Bobbin size: tube length: from 180 to 280 mm with a bobbin diameter of 32 to 72
mm. Length 350 mm upon request.
Take-up: cross-wound packages: winding traverse 110, 152 mm, taper 0° ÷ 5°57’,
maximum diameter 320 mm.
Take-up speed: 400 ÷ 2200 m/min with continuous adjustment.
Winding unit
Grooved drums: in special, treated cast iron, directly controlled by the motor in axis.
Electronic anti patterning system (standard).
C.A.P.: electronic type with computerized control of the drum-package diameter ratio
(optional).
Package taper increase: 0°÷5°, mechanical type, electronic only with C.A.P. (optional).
Axial displacement: with individual motor (optional).
Electronic clearers: Uster, Loepfe with global and continuous yarn and splice
control. Other manufacturers on request.
Splicer: air type. Water, Twinsplicer, Heat-Splicer, knotters (optional).
Yarn tensioner: a tension section, controlled by a single drive.
Pre-clearer: Variable width.
Tensor
Waxing unit (optional) deflection type.
Wax finished detection probe (optional).
Booster: tension reducer.
Meterage: standard or precision device (optional)
Counterweight: standard pneumatic device or self-adjusting (optional)
Machine body
Package conveyor belt: single lot towards the headstock.
Belt cleaning system: for the belts of the machine body and bobbin loading station.
Lighting along the machine (optional).
Travelling blower/suction unit: programmable control frequency and unloading at
machine headstock or centralized (optional).
Dust removal system in the unwinding area consisting of single suction nozzles with
a centralized dust collection box in the headstock (optional).
Computer (located in the section next to the bobbin loading station)
Centralized electronic adjustments: machine data, processing parameters, air
splicer working parameters, yarn tensioner pressure, V.S.S., electronic modulation.
Setting, collecting and displaying production data: of winding units, bobbin loading
station, doffing trolley, display of the peripherals’ alarms.
Headstock
Centralized pneumatic adjustments: package cradle counterweight, splicer air
pressure.
Machine control panel
Package unloading system
Doffing trolley: automatic package doffing, insertion of the cone on the spindle
head, cycle time: 13,5 seconds.
Double doffing trolley (optional).
Cones feeding: individual cradle on each winding unit.
Centralized cone magazine (optional).
Double centralized magazine (optional).
Bobbin loading station
Bobbin tail pick-up station: modular up to 3 stations, capacity per station 1,440
cycles/hour.
Tube cleaner: capacity 240 tubes/hour (optional).
Bobbin feeding
Loading: tipper located along the machine’s axis and vibration system to thin out
bobbins. Maximum capacity 3,000 cycles/hour.
Overall dimensions and installation layout
2925 (SM) - 2885 (SBB) - 2860 (E)
Technical summary
8T
2
3
4
5
6
4
5
2
6
4
2
6
8
5
3
mm
18930
20210
20850
21490
22130
22770
23510
24150
24250
24790
25530
26270
28830
30110
32230
32970
(L)
max. 1330
min. 550
max. 840
min. 700
max. 1240
max. 260 kg
L
1020
1100
1200
1330
B
660
720
790
890
H
2990
3060
3150
3260
We reserve the right to modify the
characteristics of the machines described
herein without prior notice. The data given
in this brochure are not intended as a
guarantee. Savio machines are equipped
with safety devices in compliance with
existing regulations.
31
Savio Macchine Tessili S.p.A.
33170 PORDENONE (Italy)
Via Udine, 105
Tel. +39 0434 3971
Fax +39 0434 397599
E-mail: [email protected]
www.saviospa.com
32
SAVIO (Shandong)
Textile Machinery Co., Ltd.
No.6 Torch Industry Park, No. 2166
Chongwen Dadao,
High&New Tech Industry
Development Zone, Jining,
Shandong, P.R. China 272000
Tel. +86 0537 2395206/101
Fax +86 0537 2395216
E-mail: [email protected]
SAVIO INDIA LTD.
Nallattipalayam, Tamaraikulam - Post
Pollachi, Coimbatore - 642109
Tamil Nadu, India
Tel. +91 4259 304555
Fax +91 4259304567
E-mail: [email protected]
Savio Advertising Dpt. - Foto: Riccardo Maria Moretti - PN - Edizione 06/2013 - inglese-cinese
Polar E Premium