Rotor Spinning Machine R40

Simple to set and to operate
Labor intensive and long lot changing times are a thing of the  past with the new R 40. The inverter technology which has  been introduced makes it possible to perform all settings comfortably and rapidly on the large touch-screen of the machine center. Specifi c requirements from the technicians, as well as large can and package sizes result in long machine running times without operator costs.

INVERTER-CONTROLLED CENTRAL DRIVES
Modern inverter technology has been implemented consistently into the new R 40. All drives can be set centrally and are infi -nitely variable. This standard sets newbenchmarks for operating the R 40. The easy settings of all machine parametersbring advantages at the start of a lot and during the optimization of currently-running production.

COMFORTABLE SETTINGS
All machine settings are made on the touch-screen of the machine center. Opening roller speeds, winding angle, tension  draft and anti patterning can be set comfortably and quickly  at the machine center. The traversing stroke can be set for the  VSB gear box on the machine display, and the package build adjusted to very diff erent yarn numbers.


SPECIFIC 3-STEP OPERATOR GUIDE
The visualization concept of the R 40 is well-thought out and  guides the operator objectively. Personnel are called precisely to the R 40 with a three colored signal lamps at both machine  ends. The settings of this signaling can be selected individually for the spinning mill organization. It acts as the initial indicator, e.g. for removing packages, repairing a robot or for a machine malfunction.  A lamp at the section indicates either a malfunction at a spinning position or a missing sliver. Two colored LED's at the individual spinning position signal whether the robot could not
piece up or whether a technical alarm exists.

LARGE YARN PACKAGES FOR CONTINUOUS OPERATION
Packages of 6 kg or up to 350 mm in diameter set the standard. Then there are 18 ½"sliver cans in two straight rows, 20"in three rows, or CUBIcans with, e.g. 30 kg capacity for longest running times

FASTEST ROBOT
Yarn-like piecing with AEROpiecing technology Extremely effi cient robots with the shortest piecing timeSimplest robot setting with XPS Travel of the robot is optimized using the intelligent Drive System iDS


HIGHEST PRODUCTIVITY
Machine lengths up to 500 rotors with rotor speeds up to  160 000 rpm  Lower energy consumption through inverter technology and  AERObearing at high productivity
Minimal operator costs, using large can and package sizes of  up to 6 kg (350 mm)
Superb package build at delivery speeds up to 350m/min maximum

BEST YARN QUALITY
Best running performance resulting from the adjustable trash  extraction with the BYpass Highest yarn quality from the fi xed fi ber-beard support and  the SPEEDpass
Broad spinning component palette for optimal yarn construction Unequalled yarn quality with man-made fi bers with the  special opener unit
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MAXIMUM FLEXIBILITY
Inverter operation for rapid lot change and optimization  of quality and productivity while the machine is running 1, 2, 3 or 4 robots with service stations for eff ective
robot service  Flexible through the overlapping of the robot working areas,  which can be set at the machine center  Slub yarn, Multicount and Multitwist are possible, as an
additional feature, at full machine length


Speed and precision for productivity and qulity

Together with the spinning box, the robot is of central importance. The yarn quality in the area of a piecing, as well as the  machine effi ciency, and thus the productivity, are impacted by  the robot.

SHORT STOP AT THE SPINNING POSITION
The R 40 robot conducts many individual tasks at the spinning  position, e.g., changing full packages, placing empty tubes,  cleaning the rotor, and feeding the yarn into the rotor. The stop at the spinning position only lasts 25 seconds. Modern  robot control permits parallel module operation at maximum  speed. The short cycle time makes it possible for the same  number of robots to service more spinning positions without any reduction in machine effi ciency.

LASER GUIDED POSITIONING
Centering on the spinning position with millimeter precision  cannot be guaranteed using mechanical methods over extended periods. Using the new, high precision, laser-controlled centering on the new R 40, this is both reliable and possible  without any wear occurring. The robot stops precisely at each spinning posiion. Reliably and accurately, the robots carry out  the piecing operations.

EFFICIENT ROTOR CLEANING
An effi cient rotor cleaning is a precondition for optimum  piecing quality. Potential sources of problems, such as, e.g.  trash particles in the rotor grooves must be removed effi ciently. Rieter follows a new path with the patented VARIOclean rotor cleaning. A rotating cleaning head with two scrapers and three compressed air jets nozzles is brought into the rotor. The rotor groove is are cleaned out with the scrapers and, in addition, the rotor groove and the entire rotor wall is cleaned by compressed air. Clean rotors guarantee quality piecings and yarn quality


SIMPLE SETTINGS WITH XPS
The conditions for an optimal piecing quality are set with  VARIOclean and AEROpiecing. Using XPS, the eXpert Piecing System, the robot is set up in an  instant. The data for a lot change are transmitted from the machine center to the robot. Only the fi ber material to be spun  must be selected at the robot. For the remaining 6 parameters  in the expert system, the robot refers back to the data base of thousands of stored robot settings. The XPS suggest settings for the 6 parameters and these can be accepted by pressing a button. The robot then operates at high effi ciency and with yarn-like piecing quality. A possible fi ne tuning, such as the adjustment of the twist or the mass, is carried out by simply adjusting some of these 6 parameters.

PIECING QUALITY REMAINS THE SAME
The robot controls and monitors the piecing procedure and  thus assures that the procedure remains the same. The innovative AEROpiecing concept which feeds the yarn tail of defi ned length into the rotor from pneumatic storage is the key to a  consistently good piecing quality.

PROBLEM-FREE MAINTENANCE
The modular construction of the robot allows easy maintenance.  Each module can be moved independently, manually or by using  the robot control system. Making mechanical settings for the robot, and the removal of any malfunctions is extremely simple,  and this success motivates the technicians to give their best  performance. With simple malfunctions, the robot cycle is simply stopped; the robot goes back to its initial position independently and moves on to the next spinning position. The feedback from th R 40 technicians is overwhelmingly positive; based  upon more than 1 500 R 40 robots which are running in the  fi eld. Rapid coordination and simple maintenance, successful removal of malfunctions are only a few of the advantages quoted.

LARGE GRAPHIC DISPLAY
All piecing parameters are shown clearly on the robot display. Robot effi ciency and further information can be called up quickly.

The successful R 40 machine concept is designed for high productivity with a maximum machine length.

MORE FLEXIBILITY WITH 4 ROBOTS
The R 40, with a length of up to 500 rotors can be equipped  with up to 4 robots. Each robot is assigned to a certain position from the maintenance concept. All spinning positions are  served by the remaining robots while one robot is in maintenance. There is no loss of effi ciency. The working area of the  robots are assigned at the machine center and can overlap. The intelligent Drive System iDS off ers a further optimization. The  machine center coordinates the robot travel area and thus optimizes the effi ciency of the entire machine.

RELIABLE AND SERVICE-FRIENDLY ELECTRONICS
The running speeds are monitored by the inverter and additionally by sensors mounted on the drive shafts. Any deviations are  recognized immediately by this double monitoring system arrangement and the machine is stopped. Thus the production of inferior yarn quality is avoided.

EXTENDED CLEANING INTERVALS
Many improvements have been made to extend the cleaning intervals of the new R 40. These improvements save 1 to 2 cleaning intervals annually and thus increase the productivity time  signifi cantly.
AERObearing, grease and oil free
SC-R spinning box with the best self-cleaning
Robots with the VARIOclean rotor cleaning
Central lubrication feature

Maximum output with effi cient energy utilization
The increasing energy requirements world-wide are leading to  steadily increasing costs. For many years Rieter has placed the  topic of energy savings in the foreground of new developments.
The R 40 energy requirements have been reduced steadily over  previous machine generations with a parallel increase in productivity.

INVERTER AND ENERGY-SAVING MOTORS
The integration of inverters combined with the central drive of  the R 40 has permitted the elimination of gear boxes. This way,  power is transmitted directly without loss. The energy consumption has been reduced further by using modern, energysaving motors. The energy requirements of the new R 40 have been reduced by 7%.

ENERGY-SAVING BEARINGS AND LUBRICATION
A further area for saving energy is in the bearing technology  and the use of lubrication. Rieter took advantage of the expertise of innovative partners for the R 40. These bearings have  the best running properties and are energy-economical. Modern bearing technology, combined with high effi ciency lubricants is an important module for reducing energy consumption.

NEW ROTOR GENERATION
The performance of the new x-rotors have been enhanced considerably compared with conventional rotors: Up to 12% higher speeds and up to 5 watts lower energy consumption, and  with better acceleration and braking performance.
The key to these developments is extensive computer simulations and an ISO certifi ed fabrication process


ENERGY EFFICIENT VACUUM SYSTEM
The fan, used to generate the vacuum in a rotor spinning machine, is the second largest energy consumer. The vacuum level is infl uenced by the build up of the fi lter mat. With the R 40, Rieter is the sole manufacturer to follow the route of combating the problem at the source. When the fi lter gets clogged, the vacuum falls. The machine control system starts an eff ective fi lter cleaning process automatically as a function of the vacuum level. The set vacuum level is again operative after this cleaning cycle. The vacuum remains constant with unchanged low energy consumption by its highly effi cient main fan. As an option, the waste in the fi lterboxes can be removed centrally and automatically.

Cooperation with specialists
The R 40 rotor spinning machine combines large numbers of functions and systems. Yarn clearers and slub yarn devices are examples of advanced technology sub-systems. Rieter takes advantage of the knowledge of specialized suppliers for these options.

YARN CLEARER SYSTEMS FOR ALL REQUIREMENTS
Yarn clearers are an absolute necessity for modern rotor spinning machines. These monitor the yarn in terms of its quality within predefi ned limits. The Quantum Clearer 2 from Uster with optical or capacitative sensor or the Barco yarn cleaner with optical sensor are available for the R 40. Both can be equipped with the foreign fi ber detection option. The R 40 replaces the recognized yarn faults with yarn-likeAEROpiecing piecings of the highest quality.


SLUB YARN DEVICES FROM WELL-KNOWN MANUFACTURERS
Current fashions defi ne which yarns can be off ered successfully on the market. Thedemand for slub yarn remains high. The simplest way to create an eff ect in the yarn is by using a special opening roller. These generate eff ects which are smaller than the rotor diameter, and which are random and not programmable.
Working with Amsler and Caipo as partners, Rieter off ers a selection of two eff ect yarn devices for the R 40. Soft and hardware interfaces are defi ned. Fitting can be carried out easily and secure. The R 40 can be supplied from the factory with a Caipo device for slub yarn, multi-count and multi-twist.

AUTOMATION POTENTIAL FOR PACKAGE REMOVAL
The removal of the produced yarn packages has a steadily increasing importance as deliveries increase. The R 40 off ers a universal interface to adapt the central package removal or palletizing systems. These systems support productivity and guarantee independence from operator availability.

CENTRAL TRASH DISPOSAL
The R 40 now has a very generously dimensioned fi lter box for the disposal of trash from the spinning process, and separately from the robot. Both fi lter boxes are prepared for connecting up to a central trash disposal system. Specialized suppliers can connect their systems and control the trash disposal centrally. Operating personnel are relieved of this task, enhancing the productivity of the achine.

BEARING AND DRIVE TECHNOLOGY
Drive technology becomes more signifi cant as the spinning machines get longer. The drives must operate reliably, consume little energy and permit a secure control by the machine control system. Energy saving motors, quality bearings and lubricants lower the energy consumption on the R 40. On these topics, Rieter also guarantees its customers the know-how of international specialists through close collaboration.

AUTOMATED SPINNING MILLS
CUBIcan cans contain large quantities of sliver. Transportation units without a driver -AGV's- can move these to the R 40 automatically. The transportation units exchange full CUBIcans for empty ones. The R 40 robots are equipped with an additionalmodule, the ROBOfeed. Using this, the robot takes the sliver from the can, brings it into the spinning position and starts the spinning process.

Automatic set-ups are frequently encountered in package removal. Systems collect the packages from the machines for a centralized or decentralized palletizing. Such systems have already been installed in many R 40 spinning mills.

LATER RETROFITTING POSSIBLE
The technical and technological development of rotor spinning strides forward. The needs and requirements of the market change and our customers must be able to react to these. New developments are constructed in such a way that they can be
retro-fi tted to older versions if at all possible. These upgrades off er advantages to the customer in terms of productivity, yarn quality and machine service life

Quality has a name

Rieter has established a name for the rotor yarns from the R 40:  the trademark ComfoRo®. Rieter has built partnerships with  leading suppliers of the textile chain. Together, experience and  know-how have been gathered, covering the entire downstream  processing. This know-how is made available to our customers.  Yarns are produced and designed for the fi nal product, and thus  off er a decisive market advantage. ComfoRo® yarns are conquering the new markets in Asia. Articles which until now have  only been produced exclusively locally with ring-spun yarn can  now be replaced with more economically produced ComfoRo® yarns.

UNIQUE YARN QUALITY
ComfoRo® is based on the unique yarn quality of the SC-R spinning box and the yarn-like piecings with AEROpiecing technology. Thanks to XPS this high piecing quality can be achieved easily and safely. ComfoRo® yarn is characterized by the best properties in the downstream processing.

PRE-SET YARN CHARACTERISTICS
The yarn must already be produced with the defi ned required profi le for an optimum result to be achieved in the end product. Here not only the know-how from Rieter is necessary, but this must fl ow together with that from the partner in the downstream processing. Yarn properties and yarn characteristics are optimized by the selection of spinning elements suitable fort  the application. The ComfoRo® rotor yarn is optimized for the following process and thus delivers the best results in the fi nal
product.

ECONOMICAL ComfoRo® PROCESS
The production costs per kg of yarn play an important role. Signifi cantly fewer machines with maximum productivity, reduced power consumption and space requirements, less operating and maintenance personnel are characteristics of the Rieter rotor spinning mill.

ECONOMICS FOR THE DOWNSTREAM PROCESSING
ComfoRo® weaving yarns are characterized by good unwinding  behavior, low sizing pick up, and cause low fl uff on high performance weaving machines. ComfoRo® knitting yarns are  characterized by a defi ned hairiness and low twist. A multiplicity of short fi bers guarantees a good unwinding behavior for  waxed yarns, and a pleasant soft hand. The hand, the softness  can be improved further by using fi nishing technologies. ComfoRo® yarns, and high value products made from them, are enjoying a steadily increasing appreciation in the marketplace. Further information on ComfoRo® can be found under www.comforo.com

Production units with low energy consumption
Compact production units such as the Rieter Rotor System offer the best opportunity for the best productivity with low energy requirements. Highly productive machines from the blow  room through the rotor spinning machine R 40 require fewer
machines, use less space, and lower the costs of air conditioning and illumination.
HIGH PRODUCTIVITY, MINIMAL SPACE REQUIREMENTSThe Rieter Rotor System stands for an appropriate maximum productivity with low space requirements. From the direct process, i.e. card C 60 with an integrated RSB module, or through the classical process with 2 drawing passages for fi ne yarn of the highest quality, the Rieter Rotor System off ers all options. Rieter machines have low energy and space requirements for maximized productivity. The production costs per kilogram of yarn are at a signifi cantly low level.


AIR CONDITIONING
The high production machines in a Rieter spinning mill need less space. Energy saving machines emit less heat into the surroundings. With fewer machines in combination with a compact building, the costs for air conditioning are signifi cantly lower than for conventional systems. Savings of more than
10% can be achieved.

♦ References

► https://www.rieter.com

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