Comoli’s new pirn winder E200: a revolutionary concept combined with cutting-edge technology

Comoli’s E200 winder

Comoli’s E200 is a spindle driven winder designed to reach a speed of 3500 m/min that makes it suitable for direct spinning lines for continuous filament yarns, both multi-filament and mono-filament, of polyamide 6 and 66, polyester, polypropylene and other chemical fibers.

It provides an extremely precise package formation, based on parallel random winding combined with electronic traverse system. It offers the possibility of designing the shape and the tapering of the bi-conical output package, with both symmetric and also asymmetric (pineapple structure, for example) package sides.

The initial yarn string-up operation, by means of a suction gun, is made particularly fast and efficient thanks to the software controlled traverse system that enables the accurate positioning of the traverse yarn guide, ready for taking the yarn, still in front of the paper tube slit with the spindle already rotating at full process speed, in order to create a very neat and stable reserve tail for the bobbin.

The long-time proven chuck spindle provides excellent stability in a wide working speed range. Its pneumatic activated system for clamping and releasing the tubes is secure, efficient and operator friendly. The very clean construction of the whole chuck aggregate eliminates trapping points for yarn on its exterior surface thus reducing the frequency for cleaning and maintenance of this important part of the winder.

The rpm speed of the bobbin-holder spindle is adjusted during each winding cycle through a PID controller that precisely reduces the number of revolutions as the bobbin is growing. In this respect the control technology offers two possibilities in terms of the control variable used as reference: either the yarn tension measured by a sensor based on loading cell or the actual package winding diameter measured by a radar sensor. Both methods of control are proven to ensure a highly precise winding speed control over the whole bobbin construction cycle, which turns into a very stable and even yarn tension by unwinding.

The spindle drive utilizes a powerful yet low energy consumption PM synchronous motor, while the electronic traverse system is geared with a stepper motor.

The E200 is a compact and versatile winding unit that can easily be adapted to many different configurations, both under existing or new spinning lines and in second step machines for the final transformation of partially oriented filament yarns.

Thanks to this new pirn winder, Comoli recently developed a new series of draw-winding frames – the DWF. It offers a lot of new possibilities in the field of conversions of existing spinning lines as well as for new installations.

The DWF is a new concept of drawing and winding frame that combines a common drawing stage for multiple ends with a winding stage using individual E200 pirn winders. Born as a revolutionary idea to provide a single step spin-draw solution for fine denier mono-filament yarns (from 8 to 33 dtex), directly generating bi-conical bobbins on cardboard tube as final output of the process, the DWF soon became attractive also for the production of multifilament textile yarns of PA6 and 66, as well as PES.

The DWF offers an interesting opportunity to revitalize old existing spinning lines of LOY-MOY-POY and increases their efficiency and productivity by transforming them into a single step spin-draw configuration. The DWF is conceived as a very flexibly platform, capable of being adapted to most of the existing spinning layouts, where space and adaptability are critical factors for revamping programs. This platform is integrated with the specific drawing field designed for up to 8 ends processed together and with the E200 winding units, one for each end.

Through the common drawing field, the multiple ends are drawn by means of a sequence of cold and heated godet rolls where the mix of mechanical properties of the yarns are fixed. After drawing and relaxation, the yarns are distributed to each respective winding unit by means of a specific space-saving fan-like layout. This fan-like yarn distribution has become a distinctive feature of all the DWF modules and it’s very important, not only for its effect of compacting the space, but especially because it was conceived as key technological solution to perfectly equalize all the yarn paths. From the last let-off godet roll all the yarns are diverted to each respective spindle (the E200 winding unit) by means of individual paths having exactly the same length and same geometry with equal angles and deflections to insure uniformity from end to end. The result is a unique combination of multiple ends processing, and strictly equalized and consistent output quality, matching the requirements for higher productivity with the most demanding quality standards.

Thanks to the smart design of the DWF modules with an open machine front that provides full accessibility and maneuverability, the operator’s routine for stringing-up, doffing and basic handling is carried out in a simple, friendly and efficient way, thus helping to achieve a significant containment of labor costs.

With the DWF producers have the possibility to increase their competitiveness of their offerings by reducing the overall process costs and approach the market with a new product that can meet very specific requirements, open up more profitable niches or expand wider growing segments.