Carpet
Volkmann CC
competence in twisting
competence in twisting
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CarpetTwister / CarpetCabler
Oerlikon Saurer is more than a brand Oerlikon Saurer is a Business Unit in the textile segment of the globally successful technology group OC Oerlikon. With groundbreaking technological innovations, Oerlikon Saurer and their product lines Allma and Volkmann are the leading international suppliers of top-performing twisting and cabling systems. For decades already, the Allma Product Line has been constantly setting new technological milestones in twisting technology. Allma production systems offer leading technology all over the world for tire cord and technical yarns. For more than 100 years already, the name of Volkmann represents high-quality twisting machines. The global success in the market segments staple fibre yarns, glass filament yarns and carpet yarns is based upon years of close cooperation with our customers.
Competence in Twisting – Carpet Yarns For many years, Oerlikon Saurer has been the leading international supplier of twisting and cabling systems. Together with the extensive range of services which are geared to customers' needs, an attractive overall package is available, ranging from project planning through to service guarantees and procurement of original parts for all machine generations. With their twisting and cabling systems for producing carpet yarns, Volkmann offers an optimum of variability and flexibility. Even more, the name of Volkmann stands for an extremely motivated team, top quality and an infrastructure meeting all requirements of today and tomorrow, from development and research through to customer service.
CarpetTwister / CarpetCabler
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CarpetTwister
Why are carpet yarns twisted on Volkmann two-for-one twisters? There are two basic reasons for this:
The particular quality and high productivity of the twisting process are the most important factors here.
In order to produce a stable, open
In the two-for-one twisting process, each mechanical spindle revolution results in two twists in the strand.
pile yarn at low costs. This applies to single-end BCF yarns, for example, for the production of carpets using the tufting process. This process is generally referred to as uptwisting. or In order to produce a particularly durable yarn for woven carpets. In this case, preference is given to staple fibres, wool or polyacrylate yarns, or polyamide, polypropylene and various blends specifically used in carpet production. The process used in this case is classic two-forone twisting.
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CarpetTwister / CarpetCabler
The strands are economically twisted to the degree required to give an even pile. Dense, uniform, voluminous carpets are especially popular because of their attractive visual appearance, durability and service qualities.
CarpetCabler
Why are carpet yarns twisted on Volkmann direct cabling machines? Cabling is a mechanical yarn upgrading process. Twisted yarns are ideal for ensuring the formation of a high-quality pile during the production of carpets. With the direct cabling process, two yarns are twisted around each other in a single step without the individual strands themselves being twisted. This ensures excellent cohesion, and thus also a better degree of fibre support. The pile is both upright and stable once it has been incorporated in the backing fabric during tufting. In contrast to the two-for-one twisting process, the yarn balloon contains only one yarn with an accordingly low level of air resistance. Energy consumption levels are thus also significantly smaller.
Because only one yarn is drawn from the pot, double-length feed packages can be processed in one loading. This ensures long operating times while producing substantial knot-free lengths of cabled yarn. Direct cabling offers several major advantages over conventional processes, e.g.: Instead of seven handling processes for yarn packages, only three or four handling operations are required here depending on the system's organisation. Package mix-ups are avoided and packages no longer need to be transported from machine to machine. It saves up to 66% of all investment costs, 60% of all labour costs and 40% of the energy costs compared to the conventional two-stage twisting process.
CarpetTwister / CarpetCabler
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Machine cross-sections
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16
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13
15
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11 10 9
8 1 6
5
4
7 3
2
2
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1
Yarn path
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Knee lever for yarn threading
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Traverse guide
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Twisting/cabling spindle
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Yarn balloon guide
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Package stop
3
Spindle pot
9
Separator
15
Friction roller
4
Balloon limiter
10
Differential yarn sensor with spindle start/stop switch
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Cradle
5
Tension hood
11
Deflection rollers
17
Yarn guide tube
6
Yarn brake and flyer
12
Pre-take-up roller
18
Hi-Lo creel with brake
6
CarpetTwister / CarpetCabler
Main properties
With its two drive systems, Volkmann CC provides options for customisation: Individual spindle tape drive in com-
bination with a mechanical gearbox Spindle rotor in combination with
a servo gearbox Highest efficiency level Best twist quality e-save spindles for significant en-
ergy savings Universal spindle for greater flexibility Quality monitoring Processing all yarn types State-of-the-art machine handling Ergonomic creel, optional with
pneumatic support Creel tensioning unit for custom
yarns Knee lever means free floor space Pneumatic yarn threading Reduced maintenance requirements High accident prevention
CarpetTwister / CarpetCabler
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Drive concepts Individual spindle tape drive with double-eccentric gear
CarpetTwister and CarpetCabler from the Volkmann Product Line have been successfully used to produce high quality, high economy yarns for quality carpets and other textiles for decades. The universal hollow-shaft spindle allows the simple conversion from the twofor-one method to the cabling method and vice versa. The tried and tested individual spindle tape drive and double eccentric gear generate yarn take-up speeds of 8,000 rpm and delivery speeds of up to 120 m/min. These major features stand for a completely sturdy and consistent mechanical drive concept. Main advantages 2 machine sides produce independently of each other Sturdy mechanical drives with individual spindle tape drive and
double-eccentric gear Economical machine concept Tried and tested textile components for high yarn quality Best cross-package quality Easy machine handling and maintenance
Individual spindle tape drive Adjustable spindle speed on each machine side by means of belt pulley or,
optionally, infinitely variable by means of a frequency inverter on the potentiometer Drive power by means of a shaft assembly with cylinder discs Automatic spindle stop in the event of sliver runout or yarn break No yarn contamination because the drive is isolated from the textile area Co-ordinated speed of all spindles being driven Yarn path monitoring ensures the yarn grade
Double eccentric gear Different take-up speeds on each side Front and rear feed gear area for setting the twist, cross-
ing angle and overfeed speed are oil-free and easily accessible The eccentric disc area for driving the traversing mechanism is fitted with an oil circulation system Optimum package building with perfect take-up package edges is implemented by means of the electronic antipatterning device
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CarpetTwister / CarpetCabler
Motor spindle with a servo gearbox
Combined with a servo gearbox, the innovative motor spindle implements a spindle speed of up to 10,000 rpm and a delivery speed of up to 150 m/min. This efficiently solves the most exacting demands on flexibility, yarn quality and machine handling. Main advantages 2 machine sides produce independently of each other Innovative motor spindle with a servo gearbox Tried and tested textile components and monitoring for the highest yarn quality Optimal cross-package quality Shortest conversion time and simplified handling Higher operating comfort Reduced maintenance
Motor spindle Innovative spindle drive by means of asynchronous motor with monitoring per central inverter on each machine side Spindle speed monitoring for each individual spindle Yarn path monitoring ensures the yarn grade No yarn contamination because the drive is isolated from the textile area
Servo gearbox Servo gearbox with FI-regulated motors for overfeed units and spindle drive, as well as servo motors for the traversing mechanism Infinitely adjustable amount of twist and delivery speed Individually adjustable yarn reserve, traverse variation, flanged-bobbin form and optimisable anti-patterning device Low maintenance, oil-free structure
The handling time for setting work is reduced to a minimum since yarn lot data is saved and can be activated at the press of a button. As a result, the machine is highly flexible, operator-friendly and very economical.
CarpetTwister / CarpetCabler
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Central operating and control unit
Machine with motor spindle The “Power Panel” central operating and control unit controls, monitors and reports on the current production data. The Power Panel touch screen guarantees that the machine is set quickly and precisely by means of easy input. The following batch data are saved and can be retrieved easily for conversion: Yarn count and amount of twist Spindle speed Crossing angle S/Z setting Length shutdown Anti-patterning device Notebook function As an option: Lot data management Traverse variation Central transfer tail length for block doffing
Machine with individual spindle tape drive The operating panels are arranged on the face of the drive section on each machine side. Operating components and displays Standard version: Display unit for - Spindle speed - Production speed - Twist turns - Time or length shutdown - Operating hours counter Fault indicator S/Z key switch with indicator lamps Start button Stop button EMERGENCY OFF mushroom button Pressure indicator, Volcojet or Creeljet Pressure indicators for pneumatic yarn path monitoring
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CarpetTwister / CarpetCabler
Special version: Potentiometer Amperemeter Start and stop button for package conveyor belt Control cabinet ventilation ON Shift yardage counter
Adjustability to twisting, up-twisting or cabling
Ball yarn brake The newly developed ball yarn brake covers the complete yarn tension range. A change to a different brake capsule, as with the usual capsule brake, is not necessary. The brake tension, generated by a spring-loaded ceramic ball, is easily adjustable in 24 steps without additional handling. During twisting and up-twisting process the actual brake adjustment is clearly visible. The advantages of the ceramic ball are: Low weight No corrosion Wear resistant
Universal hollow shaft spindle The universal hollow-shaft spindle of the CarpetTwister and CarpetCabler allows the simple conversion from the two-for-one method to the cabling method and vice versa. Gentle yarn guidance is ensured by high-quality, wear-resistant surfaces along the yarn path. The ideal design of the spindle pot allows a maximum number of feed packages. Hysteresis brake Calibrated, high-precision Volkmann hysteresis brakes have been specially developed for processing carpet yarns in the direct cabling process. They were designed to accommodate the entire count range of the various yarn grades to be processed. Due to high-quality ceramic components, the hysteresis brakes ensure a textile-friendly yarn guidance and a homogeneous yarn grade from section to section. CarpetTwister / CarpetCabler
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CarpetCabler Creel with optional creel tensioning units
Mechanical Hi-Lo creel The creel is spring-supported, which offers the following benefits: Ergonomically ideal loading position Simple high/low operation Robust and reliable Automatic locking Optimised yarn path 2- or 3-peg plug-in versions Extra plug-in options for all customer requirements Yarn brakes for every application Retrofittable preparation device Option Integrated pneumatic control system
Compensation brake The universal compensation brake ensures even yarn withdrawal and reproducibly adjustable withdrawal forces.
The benefits are: Top-quality ceramics generate the desired braking force by guiding and deflecting the yarn in a gentle and protective manner. Simplest adjustment via knob with scaling and transfer of the setting to all other points
Hysteresis brake In addition to the tried and tested hysteresis brake for pot feed packages, a special, graduated hysteresis brake for use in creels has been developed for the most exacting demands.
The benefits are: High precision Simple and fast adjustment Wear-resistant and robust ceramics Absolute reproducibility from brake to brake
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CarpetTwister / CarpetCabler
e-save spindle family
Energieeinsparungen durch e-save Spindeln Energy savings via e-save spindles e-save 285 = -15% e-save 260 = -35% Energy-optimised spindle reduces In many markets supply packages up energy consumption up to 15%. to 260 mm are being used. Standard producer packages can With this new optimised spindle/pot be used for up-twisting as well as for geometry up to 35% energy can be cabling. Due to the optimised spindle saved. geometry, the yarn count range meets For up-twisting as well as cabling all all mayor counts. mayor yarn counts can be processed Thus, the e-save 285 spindle can be and production cost can significantly used for all typical applications. be reduced.
Universal 285 Ø285
e-save 220 = -40% With the new e-save 220 spindle up to 40% energy can be saved, especially when dealing with cabled yarn – this is a quantum leap in terms of economic efficiency. The production process benefits from the different package handling. An adapted production sequence and ideal package sizes are the effect. e-save spindle advantages: Less energy per spindle Reduced power consumption per kg Same space – more production Optimum yarn quality Higher Flexibility
power
e-save 285 Ø285
e-save 260 Ø260
e-save 220 Ø220
rpm CarpetTwister / CarpetCabler
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From the spindle . . .
Storage aids Various storage facilities integrated at the twisting head facilitate and accelerate handling by the operating personnel. Yarn clamp Storage peg Tube rack Brake hood rack
Add-on balloon limiter (optional) Spindles with a free yarn balloon can be retrofitted with additional mobile balloon limiters. As a result, energy consumption is reduced and the yarn count range extended for coarser yarns.
Up-twisting according to the two-for-one twisting process (optional) Specially designed unwinding aids allow even difficult yarn grades to be processed on the two-for-one twister. The up-twisting equipment enables e.g. polypropylene BCF yarns with a small amount of twist to be processed. When an inner balloon is formed, resulting from very high unwinding speeds, the protective hood ensures that inner balloon and outer balloon are separated.
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CarpetTwister / CarpetCabler
. . . to the take-up area . . .
Sensor, clamping and cutting device In the event of a yarn break, a clearly visible signal is issued by this device, the second yarn is clamped and cut, and ancillary functions such as spindle stop and take-up package lift-off are activated. This monitoring system can be centrally adjusted to a specific yarn tension value for each machine side, and responds to overload if, for example, the yarn is entangled. The new, compact design also includes the multifunction switch for starting and stopping the spindles and provides even more free space for loading the spindles. As an option, a reset option is integrated for the length shutdown for each spindle.
Cradle in four-joint design High delivery speeds are possible due to the stable cradle design. Packages can be produced with a max. diameter of 400 mm. A contact pressure adjustment system ensures that the winding density remains even throughout.
Centering disc Easily replaceable tube centering discs mounted on ball pins for minimum wear enable simple and fast changeover to different tube or cone types. Furthermore, Oerlikon Saurer ensures the customised optimisation of the required centering discs.
CarpetTwister / CarpetCabler
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. . . Volkmann machines provide optimal safety
Take-up package lift-off device With this accessory, the spindle is automatically stopped when a feed package comes to its end or in the event of a yarn break. After a delay, a paddle lifts the cross-wound package from the friction roller and stops it. This prevents the "milling effect" from damaging the wound yarn surface and safeguards the original quality of the package. These functions are triggered automatically by the yarn path control.
Safety cover with transfer tail The lead and take-up package drive sections are completely covered. That increases safety at work. A yarn guide element facilitates the production of the transfer tail.
New, magnetic safety equipment (optional) In addition to the plasma-coated standard friction and pretake-up rollers, Volkmann provides newly developed safety equipment with automatic self-activation for overloads.
The pre-take-up roller can be chromed-plated or have a hard-wearing plasma coating.
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CarpetTwister / CarpetCabler
The new friction roller is equipped with a centred or fullsurface plasma coating.
Package conveyor belt (optional) In order to improve the ergonomics, the package conveyor belt has been designed so that twisted cross-wound packages can be removed sideways at the belt exit point. This enhancement results in a further reduction in operating times and easier operator workloads when handling large volumes of yarn. The package conveyor belt can also be used as an interim storage facility for cross-wound delivery packages. A photo sensor at the end of the conveyor belt enables the synchronised removal of the packages.
Further benefits include: A wider conveyor belt, designed for removing the cross-wound delivery packages of a complete machine side Concave guide rail prevents the jamming of packages and tubes as well as the formation of trailing ends Optionally available slides at the conveyor exit belt are for continuous removal
Creel-Jet and Volcojet Tried and tested for decades, these pneumatic threading systems are activated by means of a knee lever. They make a significant contribution to reducing the operating time. Knee lever Knee lever operation achieves an ergonomically optimised workflow and improved posture at work.
Floor clearance The knee lever makes it possible to ensure clearance between the floor and machine. The area under the machine is accessible and easier to clean.
Creel-Jet The Creel-Jet is the pneumatic threading system at the direct cabling spindle. On initiation of the threading operation, the negative pressure generated causes the creel yarn to be sucked through the yarn guide tube and the hollow shaft of the spindle. The air current then guides the yarn around the pot and back up where it can again be easily grasped by the operator.
Volcojet The Volcojet has a proven track record as the Two-for-One twister spindle threading device. The compressed air pulls the yarn through the hollow shaft so that it automatically passes the brake without any additional handling. The jet of air then carries the yarn around the pot to the top. Thus the yarn can be easily grasped by the operator.
CarpetTwister / CarpetCabler
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Options
Overview of available options:
TwistControl for machines with individual spindle tape drive The central TwistControl control unit is located at the front of the drive section and is used to control and monitor the length shut down function and to monitor the speed. A touchscreen is used for operation.
The operation of the system is self-explanatory and based on menuguided operations represented by icons.
For all machine types: Add-on balloon limiter Magnetic safety device for the pretake-up roller and the friction roller Package conveyor belt Indicator lamps on each machine side
Two-for-one twister: High-speed device for up-twisting Special unwinding aids Constant-Lubritwist lubrication system
Main advantages Length measurement per spindle Speed monitoring per spindle PDC functions
Direct cabling machine: Pneumatic creel Roller, hysteresis or compensation brake for the creel
Reduction of set-up times
Volkmann CC
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CarpetTwister / CarpetCabler
Volkmann twisting machines from Oerlikon Saurer stand out due to their quality-tested sectional design. The spindles are grouped to form machine sections.
These sections are pre-set and checked before leaving our Krefeld plant. They only need to be aligned and connected at the customer's site. That reduces the set-up times prior to production considerably.
Customer Support – Security for investments, added value and product quality
As a perfect complement to their plants and components, Oerlikon Saurer offer their customers one of the most comprehensive ranges of services – from training and counselling through to supplying of original parts for decades – for your long-term market success. Training Professional instructors train your staff in practice and theory in large training centres equipped with the latest technology. Training information and dates can be found on our homepage and in the customer portal myOerlikon.com. Counselling and technological support In our textile-technological centres we give you advice on all aspects of twisting. Experienced inspectors are constantly on the road to assist their customers and in major textile markets, fully equipped service depots are at your disposal on the spot. Whether erection, commissioning, repairs or customer visits – well-founded advice and optimal care are guaranteed. Maintenance and repairs You will find support wherever your production plant is located. This is ensured by our maintenance service, our repair centres and our competent service teams. Upgrades for machines Upgrades adapt your machines to the latest technological standard in order to increase their productivity and reliability. In order to let older machines benefit from innovations, Oerlikon Saurer regularly offers you interesting upgrade packages. Original parts service In order to secure the full availability of your plant, the original parts ordering system SECOS is available to you. The ultra-fast delivery of top-quality original parts is more than a promise. Save energy costs with e-save Our e-save components provide you with innovative solutions for reducing your energy costs of existing production plants. The new e-save technology offers an impressive energy savings potential of 20 % to 35 %. myOerlikon is the new service dimension myOerlikon is the customer portal which gives answers to all questions regarding production. Its innovative modules give you full support: SECOS for purchasing, merchandise planning and stock management, and in production you can rely on the online documentation for servicing, maintenance and troubleshooting. CarpetTwister / CarpetCabler
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Oerlikon Saurer Zweigniederlassung der Oerlikon Textile GmbH & Co. KG Volkmann Produktlinie Weeserweg 60 47804 Krefeld Deutschland T: +49 2151 71701 F: +49 2151 717474 www.saurer.oerlikontextile.com www.secos.myoerlikon.com sales-volkmann.saurer@oerlikon.com Oerlikon Textile Inc. 8801 South Boulevard Charlotte, NC 28273, USA T: +1 704 394 8111 F: +1 704 393 1502 info.twisting@saurerinc.com Oerlikon Textile Far East Ltd. Room 2806, China Resources Building, 26 Harbour Road, Wanchai, Hong Kong T: +852 2866 3501 F: +852 2866 2715 info-hk@oerlikon.com Oerlikon Textile Far East Ltd. Shanghai Representative Office Room 1410 A New Town Center No. 83 Lou Shan Guan Road Shanghai 200336 P.R. China T: +86 21 6236 8018 +86 21 6236 8019 F: +86 21 6236 8981 twisting@china.saurer.com
Volkmann CC - 03-12_0.3_en • Subject to alterations without prior notice! • Printed in Germany • © The copyright of this leaflet remains with Oerlikon Saurer.