**How to Improve the Layout of Top Roller Equipment in Tight Spinning Systems**
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According to data from the 2001 Uster Bulletin, the 5% level of ring spinning and the 95% level of tight spinning are considered optimal. The advantages of tight spinning yarn are significant, and China's adoption of tight spinning has become a key factor in the textile industry's development. Many experts believe that replacing traditional ring spinning with tight spinning is an inevitable trend. Companies like Jingwei and SUESSEN have partnered to develop localized tight spinning technology. This article discusses the experience of SUESSEN’s Elite tight spinning equipment in optimizing the layout of top roller components.
**Improvement of Component Layout**
The tightly-spun upper roller component is one of the most precise parts in a tight spinning system. It consists of two upper and lower casings, with drafting positions at Rolla Pos. 1, Pos. 2, and gear transmission systems. The top roller at Pos. 2 is driven by the top roller at Pos. 1 through gears. Several improvements have been made:
First, the joint housing was redesigned from an open type to a sealed one, improving gear protection and reducing maintenance. A labyrinth seal was introduced using a positioning ring, enhancing bearing sealing performance.
Second, the outer diameter of the top roller at Pos. 2 was increased, allowing it to fully cover the suction port of the shaped tube, which helps maintain consistent yarn accumulation.
Third, the gear transmission system now includes two drive gears and a bridge gear. This design improves the draw ratio after increasing the rubber roller’s diameter, extending gear lifespan.
Fourth, the rubber roller uses an aluminum bushing without a sleeve, increasing surface roughness for better grip and performance.
**Misunderstandings About Bearing Clearance**
Bearing clearance is a critical factor for both mills and manufacturers. Many domestic spinning mills believe that small or no clearance in the top roller bearings leads to better yarn quality. However, this is a misconception. Some manufacturers exploit this belief, leading to improper installation and potential issues such as bearing sticking or poor sensitivity.
In tight spinning systems, the rubber roller is made with an aluminum bushing. Although called “no sleeve,†a slight difference (0.03–0.06 mm) is maintained between the rubber roller and the bearing outer ring to ensure proper bonding. If the bearing itself has too little or no clearance, it can lead to operational problems during spinning, causing yarn adhesion and damage.
**Testing and Clearances**
Through extensive testing, we found that reducing the radial clearance to 0.006 mm ensures smooth operation. This means the bearing outer ring’s raceway diameter should be reduced by up to 0.006 mm. Maintaining a minimum clearance of 0.006 mm is essential for reliable performance. This proves that the idea of zero clearance is not practical.
**Long-Term Protection for Bearings**
Maintaining clean and lubricated bearings is a major challenge in textile operations. Manual cleaning and refueling are time-consuming and prone to errors. If not done properly, it can cause yarn sticking and damage to the bearings.
JW-SUESSEN’s Elite tight spinning top roller equipment features a maintenance-free design. This eliminates the need for regular oiling and cleaning. The device uses high-quality, long-lasting grease that can last up to 60,000 operating hours, effectively providing lifetime protection for the bearings.
**Feasibility of Localization**
Imported tight spinning systems are expensive, and China’s textile industry is increasingly seeking cost-effective, locally produced alternatives. Domestic manufacturers have already developed advanced skills in tight spinning, making localization a viable option.
During trials, our company calculated that the cost of localized equipment is about 120 yuan, significantly lower than imported options. With established expertise and growing demand, local production can meet the needs of the industry efficiently.
Therefore, the path to localization is clear. It reduces costs, accelerates skill development, and supports the advancement of China’s textile industry.
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How to Enhance the Layout of Top Roller Equipment Through Tight Spinning
Source: China Bearing Network | Time: 2013-10-25
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