SAVIO – the advanced solution provider for link winding
Automatic winding is no more a luxury; it is now a “necessity” for all spinners. This is because automatic winding alone provides a solution to meet the increasing demands of the market for quality and productivity as well as for smooth unwinding of the yarn in the next stages of the textile process. Automation of the transfer of ring bobbins from the spinning frame to the winder – or “linking” – is another measure that enhances quality and productivity, and is fast becoming the norm.
The factors decisive in the selection of an automatic winder to replace existing manual or older generation automatic winders, or for that matter for green field projects generally, are:
- Value for money
- Reliability
- Optimum automation
- Flexibility
- Minimum labour requirement
Savio, the pioneer in link winding technology and backed with over 100 years of experience, is uniquely placed to offer the perfect solutions that meet all the above requirements. Savio Polar or EcoPulsarS winders offer numerous features and advantages that set them apart from the other technologies available in the market for link winding.
Modular layout
End finder station plays a key role in any link system and the number of end finder stations per link depends on the process material and the length of the ring frame. Coarser counts with longer ring frame need two or more end finder stations. But if the preparation happens only between the ring frame and the winder, then the last winder spindle has to receive the prepared bobbin before the first winder spindle. This is a limitation in proper bobbin distribution. Further, the prepared bobbin travelling a long distance is prone to dust and even the travelling overhead blower can disturb its preparation.
SAVIO has overcome this issue with its unique feature of ‘Modular Layout’, available in both Polar EVO and EcoPulsarS models. Here, the second (and even the third) end finder stations can be provided in between the winder heads for proper bobbin distribution. This is possible only with SAVIO winders, thanks to the sleek design of the end finder station that occupies only the space of two winder heads, which is also easy and simple to position.
High speed end finder station
SAVIO provides sleek high efficient end finder stations for its link winders, both for the Polar and the EcoPulsarS variants. The design has been completely modified from linear operation to rotary operation. This has almost doubled the preparation capacity from 900 bobbins per hour to 1500 bobbins per hour.
The end finding and preparation used to be carried out sequentially i.e. one after another in the previous design; whereas in the new design finder, while preparing one end, another end preparation is also carried simultaneously. Thus, the finder efficiency is improved significantly. Additionally, all pneumatic lines are re-routed for ease of maintenance.
Smart back-up station (optional)
Cop rejection is a major concern for spinners. There is often a minimum 1 to 2% of cop rejection due to bad build-up of cops (the so-called “Coca-Cola” shape). In general, end finding becomes difficult for the finder stations in the case of bobbins with remnants or with technological faults (alarm cops) or in case of other sorts of improperly prepared cops from the spinning process. If the finder station concentrates on those “sick” cops, it will reduce the finder’s efficiency and thus it will reject those cops after a predetermined number of attempts.
Then those rejected cops will reach the parking lot awaiting manual attention, i.e., a person assigned for that job will prepare those cops by removing some quantity of yarn manually and putting them back on track.
Savio offers a smart back-up station, as an option, that is dedicated to take care of such bobbin rejections, either from the finder station or the spindle after preparation on repeated breaks due to long thin places etc. This smart-back up station has a success rate of around 98%, which minimises manual intervention, and reduces the requirement of manpower by 25% per shift.
Spindle identification system (optional)
The development of special yarns with high value addition requires adequate monitoring at winding and spinning to identify any rogue spindle to prevent faults and their repetitions.
In SAVIO‘s spindle identification system, each bobbin carrier or peg is fitted with an RFID (Radio Frequency Identification) tag, a sort of digital notepad in which the system records the detailed “bio-data” of each bobbin transferred including such parameters as the ring frame particulars, EYC data for yarn quality monitoring and reason for rejection from both the finder station and winder spindle. This information is also important for the smart back-up station to choose the appropriate yarn end search modality.
Underground linking system (optional)
This is an advanced solution for longer ring frame links and a recommended system for a mill with space constraints in spinning/ or winding halls, with walls etc. It will also help in linking the long ring frames with unusually longer winders in case of coarser counts processing.
Savio provides this system as optional equipment with transparent underground transportation for links.
Tube loader (optional)
Savio introduced the tube loader at the exit zone to ensure each and every peg leaves the winder with an empty bobbin on it.
Sometimes, due to human error, some bobbins are taken out for test purposes but not replaced with the empty tube on the winder to ring frames. The tube loader checks the presence of the tube on each and every peg and provides a bobbin to any peg, if found empty.
Tube stripper (optional)
SAVIO provides an automatic tube cleaning system which checks each bobbin as it exits the winder to ring frame for remnant yarn for which no setting is required. Thanks to the extrusion operating system, the tubes are always protected from any kind of damage in case of tough yarns.
