Professional Documents
Culture Documents
Application Handbook
Contents
Table of contents
Status
Foreword
04.2011
Introduction
04.2011
04.2011
04.2011
Count variations
04.2011
Splice clearing
04.2011
04.2011
04.2011
Foreign fibers
04.2011
04.2011
04.2011
04.2011
04.2011
04.2011
04.2011
15 Technical specifications
04.2011
16 Appendix
04.2011
USTER QUANTUM 3
Contents
Editorial team:
Dr. Serap Dnmez Kretzschmar
Ulf Schneider
Richard Furter
Peter Schmid
April 2011
veronesi\TT\Schulung Dokumente\On-Line\Garnreiniger\UQ3\ApplicationHandbook_UsterQuantum3
USTER QUANTUM 3
Contents
Table of contents
1
Introduction............................................................................................................................ 1.1
1.1
1.2
1.3
1.4
1.4.1
1.4.2
1.5
1.6
1.7
1.7.1
1.7.2
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
2.3
2.3.1
2.4
2.4.1
2.4.2
2.4.3
2.4.4
Communication of the yarn clearer with the winding machine .............................................. 2.9
Zero point adjustment .................................................................................................................... 2.9
Calibration process on a running yarn ........................................................................................... 2.9
Yarn detector ............................................................................................................................... 2.11
Winding speed ............................................................................................................................. 2.13
3.2
3.3
3.4
3.4.1
3.4.2
3.5
3.5.1
3.5.2
3.6
3.6.1
USTER QUANTUM 3
5.
Contents
3.7
3.7.1
3.7.2
3.8
3.8.1
3.8.2
3.8.3
3.8.4
The effect of thick and thin places on the fabric appearance ............................................... 3.19
Thick places ................................................................................................................................. 3.19
Reasons and measures to minimize seldom-occurring thick places ........................................... 3.24
Thin places .................................................................................................................................. 3.25
Reasons and measures to minimize seldom-occurring thin places ............................................ 3.27
4.2
Definition of the yarn body for long-term variations (C and CC faults) ................................. 4.1
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.4
4.4.1
4.4.2
4.5
4.5.1
4.5.2
4.5.3
4.5.4
4.5.5
Relationship between the mass and diameter deviation with the USTER Calculator ................ 4.17
4.6
4.7
4.7.1
4.7.2
5.2
5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.4
5.5
5.5.1
5.5.2
Clearing limits for splice clearing (Jp and Jm) ......................................................................... 5.9
Standard way of optimizing clearing limits: Manual clearing limits entry ....................................... 5.9
Setting a smart clearing limit for splices (Jp/Jm) ......................................................................... 5.10
5.6
5.7
USTER QUANTUM 3
Contents
5.7.1
5.7.2
5.7.3
5.7.4
7.
6.3
6.4
6.4.1
6.5
6.5.1
7.2
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
7.3
7.3.1
7.3.2
7.3.3
7.4
7.4.1
7.4.2
7.4.3
7.4.4
7.5
7.5.1
7.5.2
7.6
7.7
7.7.1
7.7.2
7.7.3
7.7.4
7.7.5
7.7.6
7.7.7
7.7.8
Hairiness..................................................................................................................................... 7.22
Principles of operation of the hairiness measuring systems........................................................ 7.22
Settings ........................................................................................................................................ 7.25
Display of the hairiness values .................................................................................................... 7.27
How do hairiness variations affect woven and knitted fabrics? ................................................... 7.28
Hairiness monitoring on the machine .......................................................................................... 7.28
On-line tests versus off-line tests ................................................................................................ 7.29
Basic hairiness differences between the different spinning methods .......................................... 7.30
Practical examples ...................................................................................................................... 7.31
7.8
7.9
USTER QUANTUM 3
Contents
7.9.1
7.9.2
7.9.3
7.9.4
7.9.5
7.10
Yarn evenness (CV), hairiness and imperfections and their effect on the fabric
appearance ................................................................................................................................ 7.41
7.10.1 Reasons and measures to minimize random mass variations .................................................... 7.41
7.10.2 Reasons and measures to minimize imperfections ..................................................................... 7.43
7.10.3 Reasons and measures to minimize excessive hairiness and hairiness variations .................... 7.46
8.2
8.3
8.3.1
8.3.2
8.3.3
8.3.4
8.3.5
8.4
Classification matrix of foreign fibers with the USTER QUANTUM 3 ................................. 8.12
8.5
8.5.1
8.5.2
8.5.3
8.5.4
8.6
8.6.1
8.6.2
8.6.3
8.6.4
8.6.5
8.6.6
8.6.7
Foreign fibers and their effect on the various production processes ................................. 8.19
Methods to eliminate foreign material and frequency of foreign material .................................... 8.21
Effect of large foreign particles on the spinning process ............................................................. 8.24
Alarm options for frequent foreign fibers in yarns with clearers ................................................... 8.24
Limits of foreign fiber elimination ................................................................................................. 8.25
Process disturbances while beaming, weaving and knitting caused by foreign matter ............... 8.25
Recommended approach to eliminate foreign fibers ................................................................... 8.25
Field tests in China ...................................................................................................................... 8.26
8.7
8.7.1
Foreign fibers and their effect on the fabric appearance ...................................................... 8.30
Reasons and measures to minimize foreign fibers in yarns ........................................................ 8.33
9.2
9.3
Classification matrix of vegetable matters with the USTER QUANTUM 3 ........................... 9.6
9.4
9.4.1
9.5
Vegetable matters and their effect on the fabric appearance ................................................. 9.9
USTER QUANTUM 3
Contents
9.5.1
9.5.2
10
10.1
10.1.1
10.1.2
10.1.3
10.2
10.3
Clearing limits for polypropylene fibers .................................................................................. 10.9
10.3.1 Standard way of optimizing clearing limits: Manual clearing limits entry ..................................... 10.9
10.3.2 Setting a smart clearing limit for polypropylene fibers ............................................................... 10.10
10.4
Polypropylene fibers and their effect on the fabric appearance......................................... 10.12
10.4.1 Reasons and measures to minimize foreign fibers in yarns ...................................................... 10.13
11
11.1
Comparison of different clearing limits and article settings ................................................. 11.1
11.1.1 Comparison of various clearing limits .......................................................................................... 11.1
11.1.2 Recreate or recall of the factory settings of the default articles ................................................... 11.3
12.
11.2
11.2.1
11.2.2
11.2.3
11.3
11.3.1
11.3.2
11.3.3
11.4
11.4.1
11.4.2
11.4.3
11.4.4
11.4.5
11.4.6
11.4.7
11.4.8
Monitoring of the yarn joint process with the USTER QUANTUM 3 ........................................ 11.14
Monitoring of the settings........................................................................................................... 11.14
Splice classification.................................................................................................................... 11.14
Yarn jump monitoring (JPM, JPA) ............................................................................................. 11.15
Drum signal monitoring (DSM) .................................................................................................. 11.16
Drum wrap monitoring (DWM, DWA) ........................................................................................ 11.16
Cut monitoring CTM .................................................................................................................. 11.17
Zero point monitoring ZPM ........................................................................................................ 11.17
12.2
12.3
12.4
12.5
12.6
USTER QUANTUM 3
0
13
14
Contents
13.2
How does the USTER QUANTUM 3 differ from competing products? ...................................... 14.1
What are the main new functions of the USTER QUANTUM 3? ............................................... 14.2
What are the new quality parameters measured by the USTER QUANTUM 3? ....................... 14.3
What is the yarn count range of USTER QUANTUM 3 and which sensing method will
fulfill the quality requirement? ...................................................................................................... 14.4
14.1.6 What is new with the USTER QUANTUM 3 optical basic clearer? ............................................ 14.4
14.1.7 What is the difference to UQC2 Vegetable Filter?....................................................................... 14.4
14.1.8 What is the advantage of the USTER QUANTUM 3 for core yarns? ......................................... 14.4
14.1.9 What is the benefit of slub yarn setting in USTER QUANTUM 3? ............................................. 14.5
14.1.10 How is the PP performance of the new clearer? ......................................................................... 14.5
14.1.11 How are the repair costs of USTER QUANTUM 3?................................................................... 14.5
14.1.12 What are the advantages from a maintenance point of view?..................................................... 14.5
14.1.13 Can the USTER QUANTUM 3 is installed be winders of previous generations? ...................... 14.5
14.1.14 Why does the USTER QUANTUM 3 have a bigger housing? ................................................... 14.6
14.1.15 What is the purpose of the arrow LEDs on the measuring head? ............................................... 14.6
14.2
14.2.1
14.2.2
14.2.3
14.2.4
14.2.5
14.2.7 What is the USTER QUANTUM 3 advantage with respect to compact yarns? ......................... 14.8
14.2.8 When should I use the vegetable clearing? ................................................................................. 14.8
14.2.9 Why cannot all vegetables pass using Vegetable Matter Clearing when they are not
disturbing? ................................................................................................................................... 14.8
14.2.10 We have an USTER QUANTUM clearer or other clearer generations - can we copy
the setting because it was acceptable until now? ........................................................................ 14.9
14.2.11 What is different with the continuous count channel? Is the settings process easier? ................ 14.9
14.2.12 How can one set up the splice clearing curve? ........................................................................... 14.9
14.2.13 How can one find/identify rogue splicers? ................................................................................. 14.10
14.2.14 What FD setting should I keep for a cotton yarn? (In case of no specific requirement from the
buyer) ......................................................................................................................................... 14.10
14.2.15 USTER QUANTUM 3 has more than 40 classes, but in USTER QUANTUM 2, we
only have 23 classes- What is the purpose of these additional classifications in USTER
QUANTUM 3? ............................................................................................................................ 14.10
14.2.16 USTER QUANTUM 3 has new sensor technology in basic and FM clearing are the
results comparable to the old classification? ............................................................................. 14.11
14.2.17 Can I use the QUANTUM 3 for wet splicer applications? .......................................................... 14.11
14.2.18 Is it possible to classify foreign fibers? ...................................................................................... 14.12
14.2.19 What are the experience values for cuts in ring spinning mills with foreign fiber clearers? ..... 14.12
USTER QUANTUM 3
Contents
14.2.20 Can we compare the classification of C15 on C20 in USTER QUANTUM 3 ........................... 14.13
14.2.21 Is the USTER QUANTUM 3 classification comparable to the USTER STATISTICS?........... 14.13
15
15.2
Structure of the USTER QUANTUM 3..................................................................................... 15.2
Comparison, capacitive versus optical measuring principle for basic clearing ................. 15.4
15.4
15.5
15.6
15.7
15.8
15.9
15.10
Cut alarms, Quality alarms, Special Counters and Logbook .............................................. 15.11
15.11
15.12
16
16.3
16.4
16.4.1
16.4.2
16.4.3
16.4.4
16.5
USTER QUANTUM 3
Contents
USTER QUANTUM 3
Contents
Foreword
It is still not possible to produce a fault-free yarn in a spinning mill for various reasons.
The drawing process is not a perfect process and can produce imperfections. Another source for irregularities in ring spinning is the availability of fiber flies in the air which are frequently spun into the
yarn as well as accumulations of fiber fragments and dust at yarn guiding elements.
In ring-spinning, all fiber and yarn guiding elements, ring travelers, pressure rollers, belts and spindles can contribute to yarn faults, particularly in case of defects.
In OE-rotor spinning, the opening rollers and dirty rotor grooves are sources of yarn faults.
In air-jet spinning the formation of faults depends on the quality of the raw material and the maintenance of the spinning devices.
Natural fibers contain foreign matter which mostly cannot be eliminated completely and stickiness of
cotton can contribute to the formation of thick and thin places.
Therefore, one important rule of modern quality management cannot be implemented completely:
Preventive actions have to be taken rather than corrections afterwards! As a result, an electronic
monitoring system is required to eliminate disturbing faults in the yarn. In ring spinning the monitoring
system is located on the winding machine. This system does not only eliminate disturbing faults in
yarns, but also separates bobbins with high unevenness, high imperfections, high hairiness, etc.
For all known spinning methods of today it is necessary to have a yarn monitoring system in the last
production process of the spinning mill, which stops the production position if disturbing faults occur.
The machine must automatically remove the faults and replace it by a splice or by a piecer.
The first electronic yarn clearers were already installed on winders in 1960. At that time thick places
could be removed only. In the last five decades, the electronic yarn clearer experienced an enormous
development. In the meantime a monitoring system has been developed which cannot only remove
faults but is also in a position to provide information on quality characteristics of the yarn. In the last
years, new quality characteristics were added such as the hairiness of yarns and the quality of splices.
As physical principle for electronic yarn clearing the capacitive and the optical principle have been
established. Both principles have their strengths in specific applications. The experts of Uster Technologies will help the spinning mills to find the best solution.
With the introduction of the electronic laboratory and on-line systems the yarn quality has improved
steadily. Therefore, faults which were not removed ten years ago are found disturbing today. An example for this is the compact yarn. As a result, the requirements for yarn clearing are also increasing
permanently.
With the higher capability of the electronic yarn clearer, there is a need for more information to make
best use of these systems. We hope that our customers can fully benefit from their investment into
the USTER QUANTUM 3 with this detailed knowhow.
R. Furter
April 2011
USTER QUANTUM 3
Contents
USTER QUANTUM 3
Introduction
Introduction
1.1
In order to be able to use the USTER QUANTUM 3 with all its possibilities to its optimum, it is necessary to have a comprehensive knowledge about the clearer. It contains the experience we gained
over the years and should fulfill the following purposes:
you have some knowledge about the textile production process, particularly the winding process
you are in a position to operate a winding machine with the USTER QUANTUM 3 installed when
going through the Application Handbook
1.2
The principles of the spinning process for short- and long-staple yarns remained the same for many
decades. Changes took place especially in the field of automation and production quantity per production hour in order to reach the highest production of yarn and with a good quality at the least expenses for personnel, capital and energy. For this, a significant technological progress in each process
stage was essential.
Despite this progress and many years of experience in spinning technology, it is still not possible to
produce a fault-free yarn. Depending on the raw material and condition of the machinery, there are
about 20 to 100 events over a length of 100 km yarn, which do not correspond to the desired appearance of yarns in fabrics. This means, that the yarn exhibits a disturbing yarn fault every 1 to 5 km.
These kinds of yarn faults are places, which are too thick or too thin. Foreign fibers or contaminated
fibers in the yarn are also counted as disturbing yarn faults.
Fig. 1-1 shows the most important yarn fault categories which have to be eliminated on the winding
machine in most of the cases.
USTER QUANTUM 3
1.1
Introduction
Fig. 1-1
st
nd
rd
1 row: Disturbing thick places / 2 row: Vegetables / 3 row: Disturbing colored inorganic fibers /
th
4 row: Disturbing white inorganic fibers (polypropylene)
Yarn faults cause disruptions in the subsequent process stages, which affect production and quality.
Yarn faults, which are already processed into woven or knitted fabric, can only be removed at very
high costs or not at all. Therefore, the yarn processing industry demands a fault-free yarn from the
yarn producer. The spinner has to fulfill these demands; otherwise he cannot sell the yarn at reasonable prices.
The spinner can fulfill these demands by a combination of two measures:
1.
2.
1.2
USTER QUANTUM 3
Introduction
The measures to avoid the origin of yarn faults are numerous and start with the choice of the raw material, the maintenance of the machines up to the cleanliness in the spinning mill. Well educated, motivated personnel and an efficient quality management play also an important role.
Yarn faults, which are still produced despite all measures, are removed according to the following
principle:
Fig. 1-2
1. During the winding process from bobbin to cone, the yarn is permanently monitored for yarn faults
with an electronic device, the yarn clearer.
2. As soon as the yarn clearer detects a yarn fault, the yarn will be cut by the cutter if the fault exceeds the limits. For this purpose the winding process is interrupted.
3. The yarn fault is removed by the suction device of the winding machine.
4. Both ends, the upper yarn from the cone as well as the lower yarn from the bobbin, have to be
joined again. The yarn joint is done by splicing with a splicing device or knotting with a knotting
device. The latter is only used very rarely for special yarns. A good splice should not be recognized by the human eye. Up to date yarn clearers also monitor the quality of the yarn joint.
5. The winding process continues until the next fault occurs or the end of the bobbin is reached.
1.3
In 1960 Uster Technologies launched the first electronic yarn clearer, the USTER SPECTOMATIC.
With one single, central setting the threshold at which the cutter should be activated could be determined. Once on the market, the demands for the yarn clearer rose steadily. Since then, Uster Technologies could always fulfill the demands of the customers to their full satisfaction with innovative
clearer models.
USTER QUANTUM 3
1.3
Introduction
Fig. 1-3 shows the improvements and features since 1960 up to the eighth generation of the USTER
QUANTUM 3 of today for winding machines.
Fig. 1-3
Uster clearer generations and their additional functions for winding machines
The numerous functions of the USTER QUANTUM 3 for a comprehensive yarn control can be
summed up as follows:
Visualization of data on the display, for reports, information systems and for the subsequent process stages
1.4
USTER QUANTUM 3
Introduction
In order to define and control all these functions, various settings to fulfill all the requirements in the
textile industry can be carried out at the USTER QUANTUM 3. This stands in contrast to one single
setting of the first clearer generation.
1.4
Fig. 1-4
Frequent yarn faults and seldom-occurring yarn faults. The deviations in percent are either mass or
diameter related, depending on the type of sensor.
USTER QUANTUM 3
1.5
Introduction
The average mass increase for thick places has to exceed +75% for faults below 2 cm, 45% for faults
below 4 cm length and +30% for faults longer than 4 cm to be counted by the classifying system of
the USTER QUANTUM CLEARER. In the area of thin places the average mass of a fault has to drop
at least 20% to be counted.
Fig. 1-5
Fig. 1-6
1.6
USTER QUANTUM 3
Introduction
1.5
Classifications are used in spinning mills either as on-line monitoring system as a feature of the clearing system on automatic winding machines or as an analyzing instrument on manual winding machines in textile laboratories, and they play a very important role to analyze seldom-occurring yarn
faults.
Fig. 1-7 shows the classification matrix of this analyzing system with a few examples of seldomoccurring yarn faults for the thick place classes A1 to D4 which are assigned by the system to the
respective classes.
Fig. 1-7
Classes of the USTER CLASSIMAT QUANTUM system. The new classes are not shown in this
figure
It is obvious that the appearance of seldom-occurring faults in a fabric depends on various items:
USTER QUANTUM 3
1.7
Introduction
1.6
A basic rule in quality management is a preventive maintenance rather than corrections afterwards.
Unfortunately, this is not yet possible with the technology of today. Textile specialists in spinning mills
who have to conquer disturbing yarn faults have to find the origin of such yarn faults.
Table 1 shows a selection of sources which produce seldom-occurring faults in the respective categories. It is a collection of reasons over many years why such events happened. The classes A0 to I2
correspond to the matrix, Fig. 1-5.
Classes
A (Thick place)
Comments
A0
Extended class, mainly used for ply yarn and compact yarn
A1
A2
A3
A4
B0
Extended class, mainly used for ply yarn and compact yarn
B1
B2
B3
B4
C0
Extended class, mainly used for ply yarn and compact yarn
C1
C2
C3
(Unacceptable faults)
C4
(Unacceptable faults)
D0
Extended class, mainly used for ply yarn and compact yarn
D1
Floating fibers
D2
(Unacceptable faults)
D3
(Unacceptable faults)
D4
(Unacceptable faults)
E (Thick place)
(Spinners double)
F (Thick place)
G (Thick place)
H (Thin place)
H1
(Thin places)
H2
(Thin places)
I1
I2
B (Thick place)
C (Thick place)
D (Thick place)
I (Thin place)
Table 1
1.8
(Unacceptable faults)
(Unacceptable faults)
Classimat defects / Classification and sources of origin. New classes are not mentioned in Table 1.
USTER QUANTUM 3
Introduction
Fig. 1-8
USTER QUANTUM 3
Fig. 1-9
1.9
Introduction
As most of these yarn faults can lead to problems in the subsequent processes or are disturbing in
the end product, they must be removed from the yarn and replaced by a splice. The art of yarn clearing consists of cutting out the most disturbing faults without influencing the efficiency of the machine
too much. Therefore, yarn clearing is always a compromise.
Foreign fibers
Foreign fibers in the yarn belong also to the group of seldom-occurring yarn faults. The cause for foreign fibers are contaminations, which get crushed in the spinning process, especially by the card, and
are noticed as foreign fibers in the yarn at the end of the spinning process. Further explanations concerning this subject can be found in chapter 8, "Foreign fibers", of this Application Handbook.
Fig. 1-10
Fig. 1-11
1.10
Fig. 1-12
Vegetable in a yarn
USTER QUANTUM 3
Introduction
1.7
The USTER QUANTUM 3 is the successor of the USTER QUANTUM 2. This new clearer generation is focused on simplifying the complexities of yarn clearing and thereby enable the user to easily
and fully exploit all clearer capabilities and to optimize production costs every day. The USTER
QUANTUM 3 interprets and displays the yarn characteristics within minutes and proposes a starting
point for clearing limits with a cut forecast by pressing a single button.
One of the key highlights is the integration of the well-known USTER knowhow in the system on the
winder. Another exciting new innovation is a completely new foreign fiber clearing technology with
vegetable clearing which is able to detect all colors and separates foreign matter into two separate
pools: foreign fibers and vegetables. This separation improves the foreign fiber clearing efficiency
significantly by reducing cuts for the same quality or gets a better quality for the same cuts.
Fig. 1-13
USTER QUANTUM 3
1.11
Introduction
Foreign
matter
FEATURES
COMMENTS
N, S, L, T
C, CC
Jp, Jm
Splice Clearing
Cut forecast
Technical alarms
Textile alarms
Vegetable
Clearing
(Option)
Identification of vegetables
Polypropylene fibers
(Option)
Q-Data (Option)
Evenness (CV)
Imperfections
Class alarms
Expert
Access to the data output for Expert System and centralized data collection and reporting
Extended Classes
Tailored classes
Software pack
Hairiness
(Option)
Expert (Option)
Advanced
Classification (Option)
Lab On-line
(Option)
Table 1-2
1.12
USTER QUANTUM 3
Introduction
FEATURES
Capacitive
C15
Capacitive Capacitive
C20
C15 F30
Capacitive
C20 F30
Optical
O30
Optical
O30 F30
BASIC
FOREIGN MATTER
(Option)
---
---
---
VEGETABLE (Option)
---
---
---
---
POLYPROPYLENE
(Option)
---
---
O*
O*
---
---
Q-DATA (Option)
HAIRINESS (Option)
---
---
---
USTER QUANTUM
EXPERT 3
---
---
---
Table 1-3
Key:
X
Product Option Key (POK) is needed to have access to the feature mentioned in the header of this column
O*
Hardware upgrade required in the Central Clearing Unit 6 (CCU6) to have access to the feature
---
USTER QUANTUM 3
1.13
1.14
Introduction
USTER QUANTUM 3
2.1
This chapter explains the sensor technology and its characteristics, which is used in the USTER
QUANTUM 3. The basics of the yarn signal analysis and the yarn clearing are illustrated in the following figures and should support the understanding of the additional chapters of this application handbook.
2.2
In order to be able to monitor and to evaluate thick and thin places as well as deviations from the
nominal yarn count, the thickness of the yarn must be converted into a proportional electrical voltage.
The course of the voltage is called yarn signal.
Yarn piece with thick place
Fig. 2-1
In the USTER QUANTUM 3, the conversion is carried out either with the sensor of the capacitive
measuring principle or with the sensor of the optical measuring principle. The sensor is part of the
intelligent measuring head iMH which also consists of the electronic system to convert mass or diameter variations into a proportional electric signal.
There are very high demands for both measuring principles regarding the resolution and precision of
the results. The sensor must be able to monitor a yarn which runs with up to 120 km/h through the
sensor and to detect even very short faults. In order to achieve this, the yarn signal is determined every 2 mm.
USTER QUANTUM 3
2.1
2.2.1
Fig. 2-2
Capacitive sensor
The electrical measuring condenser (1) forms the sensor for the capacitive monitoring of the yarn
mass. This is done by two parallel metal plates, the electrodes. In the space in between (2), the two
electrodes build an electrical field when putting on an electrical alternating voltage (3). If a yarn (4) is
brought into this field, the capacitance of the measuring condenser changes. From this change, an
electrical signal, the yarn signal (5), is derived. The change of the capacitance depends, besides of
the mass of the yarn and of the dielectric constant of the fiber material used and the moisture content
of the yarn.
With the capacitive measuring principle, the yarn signal corresponds to the yarn mass, which is located in the measuring field. Changes of the yarn mass cause a proportional change of the yarn signal.
2.2.2
Fig. 2-3
Optical sensor
The infrared light source (1) and the photocell (3) represent the sensor for the optical monitoring of
the yarn thickness. The infrared light is scattered by a diffusor (2) in the measuring zone and reaches
the photocell (3). The photocell generates an electric signal, which is proportional to the light intensity.
If a yarn (4) is brought into the measuring zone, parts of the light will be absorbed by the yarn. The
amount of light, which hits the photocell, is smaller. From this change, an electrical signal, the yarn
signal (5), is derived.
2.2
USTER QUANTUM 3
With the optical measuring principle the yarn signal corresponds to the diameter of the usually circular
shape of the yarn, which is located inside the measuring field. Changes of the yarn diameter cause a
proportional change of the yarn signal.
2.2.3
Independent of the used measuring principle, the evaluation is carried out on the basis of the relative
yarn signal change in contrast to the base value. The base value corresponds to the count of the
wound yarn.
+ 200%
+ 150%
+ 100%
+ 50%
0%
- 50%
- 100%
Fig. 2-4
1. No yarn in the measuring field: in this state, the yarn signal is defined as 100%.
2. A yarn of a certain count is inserted into the measuring field. The yarn signal changes from 100%
to 0%. The change of 100% corresponds to the yarn count.
3. The yarn is moved in the measuring field. The yarn signal corresponds to the yarn evenness. The
mean value of the evenness variation is defined as 0%. 0% is the base value for the deviations of
a positive thick place and a negative thin place.
4. Thick place in the measuring field: the deviation is measured in % to the base value. In the example (Fig. 2-4), the deviation is +130%. If the signal exceeds the clearing limit set, the fault will be
cut.
5. As soon as the yarn leaves the measuring field, the yarn signal drops to 100%.
The definitions are valid for both measuring principles. The change in percent refers to the crosssection in case of the capacitive measuring principle and the diameter in the case of the optical
measuring principle.
This means that an increase or decrease of the yarn mass produces different deviations (%) of the
yarn signal depending on the physical principle of the sensor. Table 2-1 shows the relationship between the cross-section and the diameter changes.
USTER QUANTUM 3
2.3
Yarn
Regular yarn
Thick places
with double cross-section
Thin place
with half of the cross-section
Table 2-1
0% base value
0% base value
The higher resolution of the capacitive sensor is particularly helpful in areas where already small deviations from the nominal value can be disturbing for the human eye (e.g. in compact spinning as a
result of the missing hairiness).
This table indicates that the used measuring principle must always be known. Otherwise, it can lead
to misinterpretation.
Fig. 2-5 shows the relationship between the cross-section and the diameter changes.
Fig. 2-5
2.4
USTER QUANTUM 3
Example:
The mass of a thick place in the measuring zone increases by +300% compared to the mean of the
yarn. How much is the rise of the signal of the optical system? According to Fig. 2-5 the optical signal
(proportional to the diameter) increases by +100%.
Remarks: This is valid for yarn faults with equal density of the fibers esp. long, well twisted yarn
faults. For short and fluffy yarn faults the diameter deviations is more or less the same as
the mass deviation.
2.2.4
Why are there two different measuring principles for yarn clearing?
The requirements in the textile industry depend on the textile fibers and the end-use. The experts of
Uster Technologies can support the users to select the best clearer. The following Table 2-2 shows
the most important differences of their properties.
Characteristics
capacitive principle
optical principle
Proportionality
The yarn signal is the mean value of The yarn signal is the mean valthe piece of yarn which is located in ue of the piece of yarn which is
the measuring field. Length: 4 mm
located in the measuring field.
Length: 3 mm
Voluminous, visually large appearing As the number of additional fibers is The very voluminous yarn fault
yarn fault
not extremely high, this yarn fault is absorbs a lot of additional light.
recognized as relatively insignificant. Therefore, the fault is considered
as significant.
USTER QUANTUM 3
2.5
2.2.5
Environmental influences and material characteristics have different effects on both measuring principles. Therefore, for certain applications one measuring principle may be more appropriate than the
other one.
Table 2-3 shows the most important influences on the yarn measurement and the yarn clearing with
both measuring principles, respectively.
Influence
Fiber material
Colored yarns
Fiber blends
Wax
If the wax device is located below the yarn clearer, there is the tendency of a dirty measuring field. The selection of a suitable wax can keep the contamination within acceptable
limits. The capacitive measuring field is less affected by wax.
Contamination
Usually, the measuring field is cleaned to a great extent by the yarn hairiness. The
Yarn moisture
Normal variations have no influence as long as the yarn structure doesnt change.
Non-homogenous yarn humidity can lead to
unjustified cuts.
Table 2-3
2.6
USTER QUANTUM 3
Besides the yarn, the capacitive measuring principle measures also the moisture of the yarn. Therefore, and as the deviations of the yarn fault are always referred the mean value of the yarn signal, a
homogenous distribution of the humidity along the yarn should be striven for. Large variations in the
distribution of the moisture can lead to unjustified cuts.
In order to reach a high and constant production and quality, a stable climate and the avoidance of
fast changing variations of the relative humidity, respectively, are needed.
Blended yarns made out of various colored fibers (melange) / Optical measuring system
In a blend of various colored fibers with high light reflection differences (e.g. black/white), disturbances in the blend can lead to clearer cuts. This characteristics, however, can be used with the intention to control the fiber blend in such yarns.
2.2.6
Yarn clearing is the final control in a spinning mill. In order to produce the best possible yarn quality,
all capabilities of a yarn clearer system should to be used. This also includes the selection of the most
suitable measuring principle. The previous explanations and the chapter "Technical Specifications",
Chapter 15 should help to make the best choice. If you are not completely sure, please do not hesitate to contact a representative of Uster Technologies, who will be glad to assist you.
2.3
The demands of the world market on the yarn quality have risen steadily over the last couple of years,
also in regard of foreign fiber faults. Today, it is expected from a yarn clearer that it detects a single
colored fiber in the yarn.
USTER QUANTUM 3
2.7
2.3.1
Intensity
In contrast to the human eye, the foreign fiber sensor measures the contrast between the yarn itself
and the foreign fiber. The intensity of the contrast does not only depend on the color of the foreign
fiber, but also on its surface structure. The wavelength of the light sources which are used in the sensor also plays an important role. The signal which is generated by the foreign fiber sensor is defined
as the intensity of the foreign fiber. The intensity of the foreign fiber or, to be more precise, the
change of the light reflection is given in % foreign fiber signal.
For dark foreign fibers in a white yarn:
0%
= Reflection of the yarn without foreign fiber
100% = Reflection of a completely black foreign fiber
The following Table 2-4 shows some foreign fiber faults as seen by the human eye and by the sensor:
Human eye
Reflection sensor
Intensity
16%
16%
9%
32%
7%
Table 2-4
Length
The duration of the signal corresponds to the foreign fiber length. The length is given in mm.
Detailed explanations for the monitoring of foreign fibers can be found in chapter 8 "Foreign fibers".
With the multicolor light source of the USTER QUANTUM 3 it is possible to detect foreign fibers of all
colors.
2.8
USTER QUANTUM 3
2.4
In order to recognize the status of the winding machine, an exchange of information is needed between the clearer and the winder.
2.4.1
If there is no yarn in the measuring field, the yarn signal must show 100%. Dirt and changes inside
the measuring field can cause that the yarn signal is not 100% when yarn is removed from the
measuring field. With the zero point adjustment, these deviations are compensated and the yarn signal is set on 100% again.
The zero point adjustment is carried out before the splicing process, i.e. when the measuring field is
empty. If the control range is not sufficient for the zero point adjustment to set the yarn signal to
-100% (measuring field too dirty or blocked with fly), a technical alarm for the respective sensor is
triggered.
2.4.2
As already explained, thick and thin places in a yarn are registered as deviation from the nominal yarn
value in percent. Foreign fibers are registered as changes of the light reflection in percent. In order to
make this possible, the sensor has to collect know-how on the yarn first, i.e. the sensor needs a startup process on the running yarn.
The determination of the nominal yarn count, in the following called the calibration value, is carried out
automatically during the start-up of a new article and is adjusted continuously at every start of a winding position. The ADMV-value * regulates the amplification of the yarn signal, so that the nominal yarn
count represents 0%. There are separate ADMV-values for the thick and thin place detection as well
as for the foreign fiber detection.
Fig. 2-6
Calibration process. Course of the calibration process for thick and thin place clearing.
* ADMV = Analog Digital Mean Value, represents the yarn mean value
USTER QUANTUM 3
2.9
This yarn mean value is the mean value of all clearers of a group. With this value it is possible to calculate percentage deviations between two or several yarns. The ADMV value consists not only of the
yarn count, but also of yarn properties such as fiber type, moisture, color, etc. The number of the
start-ups per group and winding position during production changes (red rectangle) until it reaches the
value of 200, and because the calculated mean value is statistically stable, after 200 the count will not
change anymore.
Fig. 2-7
2.10
USTER QUANTUM 3
2.4.3
Yarn detector
The yarn detector monitors the status of the yarn in the measuring field: yarn not available, yarn not
moving, yarn moving. The yarn detector controls some functions of the machine.
Static yarn detector SYD
The static yarn detector detects, if there is yarn in the measuring field or not:
No yarn in the measuring field
SYD = turned on
0%
threshold
No yarn
-100%
on
SYD
Static yarn detector
off
Fig. 2-8
DYD = off
DYD = on
If the DYD is turned off, the winding position will not / is stopped.
The DYD is turned on by the yarn signal change, which is caused by the unevenness of the running
yarn. The sensitivity and the timing for turning on and off are set. For exceptional cases (processing of
special yarns) a manual adjustment of the yarn detector settings according to the sensor type as well
as to the winding machine type is available.
USTER QUANTUM 3
2.11
Fig. 2-9
Fig. 2-10
Use this test mode, if there are any problems with the yarn detector, i.e. if there are any winding positions which do not run or do not stop when the yarn breaks.
2.12
USTER QUANTUM 3
2.4.4
Winding speed
Fault length
Besides the mass or diameter variation, the fault length is also decisive for the evaluation of a yarn
fault.
The fault length is determined by the time, during which the fault runs through the measuring field.
Again, this time depends on the yarn speed and the winding speed, respectively.
Wound length
The clearer also determines the length of the wound yarn. The wound length is calculated from the
winding speed and the time during which the dynamic yarn detector is turned on.
Winding speed
In order to calculate the fault length and the wound yarn length correctly, the clearer needs the
information about the winding speed.
2
3
1
Fig. 2-11
The winding speed and the yarn speed, respectively, are defined by the friction drive between the
guide drum (1) and the cross-wound cone (2). The sensor (3) delivers a certain number of drum
impulses per rotation of the guide drum. These impulses are evaluated by the yarn clearer to
measure the winding speed.
Older or more simple winding machines do not have a drum sensor. For clearer installations on such
machines, the winding speed must be set at the control unit.
USTER QUANTUM 3
2.13
The winding speed which is given by the drum impulse or the setting at the control unit does not always correspond to the effective yarn speed. The yarn speed is additionally influenced by the following parameters:
Yarn displacement
Depending on the subsequent processes of the yarn, cones with various conical shapes are used.
With a cone of e.g. 915", the speed variation can be significant.
Slippage
If the guide drum turns faster than the cone, slippage occurs. Thus, the yarn runs at lower speed
through the measuring field. A yarn fault appears longer than it is in reality. Incorrect cuts during
start-up or during winding and incorrectly inspected yarn joints (splices/knots) can be the consequences in the extreme case.
Slippage occurs at a fast start-up of the guide drum or when the processed material exhibits a low
static friction. In order to avoid slippage it is necessary to set the start-up curve so that the crosswound cone starts synchronously with the guide drum. This is of special importance for the production of cross-wound cones with a large diameter.
Ribbon winding
If the diameter of the cross-wound cone stands in a even number ratio to the diameter of the
guide drum, ribbon winding can occur. The anti-patterning device, which is generated by the variation of the drum speed, avoids this. Variations of the winding speed are the result. These variations are registered on winding machines with the drum impulse sensor and thus taken into account by the yarn clearer. The desired slight slippage is not taken into account.
2.14
USTER QUANTUM 3
3.1
Introduction
This chapter will explain the classification and monitoring of disturbing thick and thin places.
Staple fiber yarns always have a specific unevenness. The reasons for their origin are diverse. At a
certain size (mass or diameter and length) this unevenness will be disturbing in the yarn.
Electronic yarn clearing is a process in which disturbing yarn faults are detected and eliminated. In
ring spinning, yarn clearing is carried out on winding machines with a winding speed of up to
2500 m/min.
Yarn monitoring and yarn clearing is based on the mean value of the yarn. This yarn value is determined by the measuring head itself. This is valid for the capacitive as well as for the optical measuring
head.
During the spinning process, it is not possible to keep the number of fibers in the cross-section constant at every moment. This leads to random variations of the mass or the diameter. Only those spinning mills with a permanent improvement process are able to keep these random variations within
close limits.
3.2
The USTER QUANTUM 3 interprets and displays the yarn characteristics with the help of the yarn
body. The powerful capacitive and optical sensors of the USTER QUANTUM 3 can determine the full
yarn body including very short and fine defects. The clearer analyzes the yarn fault distribution and
displays the yarn profile, which is called yarn body, in a few seconds or minutes. The yarn body is
simply the normal yarn with its set of expected natural variations and represents the nominal yarn with
its tolerable, frequent yarn faults. Yarn body is a new yarn characteristic, and we know from the experience so far that the yarn body changes according to the raw material and the spinning process. By
analyzing the shape of the yarn bodies out of different raw material varieties and process changes,
we can discover patterns and build up references. Based on the references, the operator can identify
changes. The yarn body becomes always wider in the direction of the short yarn variations, e.g. short
faults occur more frequently. On the contrary, the yarn body becomes smaller in the direction of the
long yarn variations.
The yarn body is a significant tool to help finding the optimum clearing limits, not only for thick places
(NSL) and thin places (T), but also yarn count deviations (later called C and CC faults).
USTER QUANTUM 3
3.1
In Fig. 3-1, the dark green area represents the yarn body and the light green area the yarn body variations, and this figure shows that the yarn body becomes wider in the direction of the short yarn faults.
The short yarn faults with a significant mass or diameter deviation from the mean value (zero line) are
considered less disturbing by the human eye compared with long yarn faults with little deviation. Short
faults also occur more often. The number of clearer cuts increases considerably if the clearing limit is
set in the green area.
The vertical scale represents the yarn mass or diameter increase and decrease, and the horizontal
axis represents the faults length in cm.
In Fig. 3-1, besides two green areas, there are also green dots which represent remaining events in
the yarn and red dots which represent cut yarn faults (disturbing events). The number of expected
fault cuts per 100 km together with setting limits are shown with red color (in Fig. 3-1, top right corner,
311,6 km of yarn was wound and the expected fault cuts for thick places calculated per 100 km is
96,0 cuts). The cut ratio will be statistically representative after running 100 km of yarn. At a winding
speed of 1500 m/min and 60 winding positions per machine, it lasts approximately 1 minute.
Fig. 3-1
Frequent and seldom-occurring yarn faults. Measured yarn length: 311,6 km.
The expected fault cuts for thin places calculated per 100 km is 4,5 (bottom, right corner). The total for
thick and thin places is 100,5 per 100 km, which is too high as a cut rate. Therefore, the clearing
curve has to be moved away from the yarn body.
Since both dark and light green areas together constitute the yarn body, it is recommended that the
clearer should not cut into the yarn body. If the clearing limit is laid within these green areas, the cuts
will increase significantly and the productivity will be lower.
3.2
USTER QUANTUM 3
Fig. 3-2
At the beginning the variation shown as the light green area is not yet stable due to the statistical calculations. But already after 30 km of running yarn the variation has stabilized and the optimization
process for the clearing limits can start. There is practically no difference anymore between Fig. 3-3
and Fig. 3-4.
If we calculate the duration of the above mentioned start-up for a link system with 23 winding positions and a stand-alone winding machine with 60 winding position, it results in the following time
spans:
Yarn length
Winder speed
Winding positions
Duration
Winding positions
Duration
4,6 km
1400 m/min
23
0,14 min
60
0,05 min
49,2 km
1400 m/min
23
1,53 min
60
0,59 min
72,6 km
1400 m/min
23
2,25 min
60
0,86 min
Fig. 3-5
Yarn body, cotton 100%, combed, knitting, 276 km (left), 238 km (right), count Nec 40, clearer C20,
yarn with 39,4 cuts / 100 km on the left, yarn with 81,8 cuts / 100 km on the right.
USTER QUANTUM 3
3.3
Fig. 3-6
Yarn body, polyester 100%, Nec 40, 523 km, knitting, (left), 382 km weaving, (right), clearer C15
Fig. 3-7
Yarn body, cotton 100%, carded, knitting, 413 km (left), 553 km (right), count Nec 40, clearer C15
Fig. 3-8
Yarn body, Nec 40, 35% cotton/65% viscose, weaving, 353 km (left), Nec 40, 55% cotton / 45% polyester, weaving, 361 km (right), clearer C15
3.4
USTER QUANTUM 3
3.3
The Fig. 3-5 to Fig. 3-8 demonstrate that the shape of the yarn body strongly depends on the quality
and the raw material of the yarn. For reasons of a better comparison the eight yarns are all of the
same count. A comparison of yarn bodies of various counts and raw material has unveiled the following:
Due to the higher irregularity the yarn body of carded yarns is wider than those of combed yarns
Since fine count yarns have a higher irregularity than coarse count yarns, the yarn body of fine
yarns is wider than those of coarse yarns
The man-made polyester cut staple fibers have a significant effect on the light green area from 0,1
to 4 cm
The highest deviation of the yarn body from the zero line in the thin place area can be recognized
at the mean length of the fibers, i.e. at about 2 cm, in blended yarns at about 3 cm.
The seldom-occurring faults (red dots) have a different but characteristic distribution. Therefore,
an automatic determination of the clearing curve can minimize the number of cuts.
The yarn body, therefore, is a significant support tool to only cut really disturbing faults and to optimize the number of cuts. The yarn body is affected by the yarn unevenness, by the number and type
of thin places, thick places and neps, by the characteristics of the raw material and by the spinning
process.
3.4
3.4.1
Classification matrix
As already described in the introduction of this application handbook, seldom-occurring yarn faults are
classified in the classification matrix of the USTER CLASSIMAT. Besides the classification matrix,
the cut thick places are divided in three groups (Fig. 3-9):
N faults: thick places from 0,2 cm to < 1 cm very short thick places (S fault)
USTER QUANTUM 3
3.5
Fig. 3-9
Fig. 3-9 shows a setting example of the clearing curve when pressing the key NSLT.
Fig. 3-10 shows the classification matrix of thick and thin places. With the help of new extended classes, the user can monitor and control critical (e.g. short and fine) defects which often determine the
fabric appearance.
Fig. 3-10
For a broad understanding of the faults, it is recommended to base the assessment for the setting of
the yarn clearer mainly on the evaluation of the yarn body and the scatter plot and less on the counts
of the classification.
3.6
USTER QUANTUM 3
3.4.2
Thick and thin places are evaluated by their visual impression, if they are disturbing or not-disturbing.
The conversion into the "language" of the clearer, i.e. the fixing of the clearing limits, must be possible
on the basis of the visual evaluation. Therefore, each modern yarn clearer must fulfill these conditions
in order to measure all thick and thin places correctly. The determined values have to correlate to the
size of the visual impression. Long thick and thin places can hardly be seen on the yarn itself, but are
disturbing in the fabric. They require optimized calculation methods.
These demands are fulfilled ideally with the USTER QUANTUM 3. It is based on the calculation
method already used in previous generations of the USTER clearers and was proven to be best.
Depending on the sensor type, the cross-section (iMH-C) or the diameter (iMH-O) are measured continuously with a repetition rate of 2 mm. This means: the clearer calculates the mass or the diameter
of the yarn continuously every 2 mm length and determines the mass or the diameter of these sections. The fault determination starts, it is exceeding the mean value.
Positive
threshold
- 100%
2 mm pieces
Fig. 3-11
Fig. 3-11 shows a yarn signal, for which a next test value is determined every 2 mm.
Fig. 3-12 shows the yarn signal of a cotton yarn with two distinctive thick places and the deviation in
percent. The first yarn fault has an increase of about 330%. In addition, one distinctive thin place is
represented.
Fig. 3-12
Yarn signal of a cotton yarn with a clearing limit of 130% above the mean (0%)
USTER QUANTUM 3
3.7
Fig. 3-13
All the displayed yarn faults of Fig. 3-14 show a classification length of 16 mm and were classified
with a thickness between 260 and 300%. This picture is taken from the library of USTER QUANTUM
EXPERT for winding.
Fig. 3-14
The shown yarn faults (Fig. 3-14) serve as examples for the previously described fault.
The example in Fig. 3-15 shows a long thick place with the classification 74% and 63 cm. If this classification point is entered into the classification matrix, it can be seen that the fault is situated above
the clearing limit.
3.8
USTER QUANTUM 3
74%
63 cm
Fig. 3-15
Example for a long thick place in the display window of the Control Unit
Long thick places starting at a length of 8 cm are classified as L-faults. The length of the L-faults is
limited at 200 cm.
3.5
The clearing limit is defined as a line which separates disturbing/cut faults from the nondisturbing/remaining faults. The course of the clearing limit is defined by setting parameters (see Fig.
3-16).
Fig. 3-16
For a good overview, the clearing limit is shown in the classification matrix. The classification matrix
corresponds always to the set parameters.
USTER QUANTUM 3
3.9
3.5.1
Fig. 3-17 shows the clearing limit as shown in the setting window of the Control Unit. At the previous
generations of the USTER QUANTUM, besides the clearing limit (NSL), the settings for the thick
place clearing with the auxiliary setting points (H1H6) is possible. Now the USTER QUANTUM 3
gives us the chance of determining clearing limits by placing a maximum of 8 set points NSL1 to
NSL8. In Fig. 3-17, we can see 4 setting points (red rectangle) and the clearing limit for NSL thick
places. By this setting method the effects of a change of the parameters on the clearing limit can be
demonstrated directly.
As soon as we enter new values at set point, the next one will appear until we reach the 8th set point.
This means after we enter the values for NSL1, set point NSL2 will appear and it will continue the
same way.
Fig. 3-17
Set points have two parameters. These are: sensitivity (%) and reference length (cm).
Sensitivity
The sensitivity (%) is a parameter for the clearing limits of the corresponding fault channel. The sensitivity setting shifts the clearing limit upwards (less sensitive) or downwards (more sensitive).
(NSL1 = 300%, Fig. 3-17).
Reference length
The reference length (cm) is a parameter for the clearing limits of the corresponding fault channel and
shifts the clearing limit to the right (less sensitive) or to the left (more sensitive) (NSL1 = 1.0 cm,
Fig. 3-17).
3.10
USTER QUANTUM 3
3.5.2
As we mentioned before, the yarn body is used for a better understanding of thick places, thin places
and it shows the nominal yarn with its tolerable, frequent yarn faults. The aim of yarn clearing is to
follow the course of the yarn body and to eliminate the thick and thin places which are disturbing in a
fabric and which are outside the yarn body. Since the yarn body is clearly visible, clearing can follow
the yarn body to minimize the number of cuts and to optimize the removal of disturbing faults. It also
prevents from cutting into the yarn body and removal of defects that don't add value to the yarn but
simply need additional splices which then could potentially break in the weaving process. In other
words the default smart limit based on the yarn body is a nearly optimal clearing limit from a quality
point of view (Fig. 3-18).
Pressing
key presents
Fig. 3-18
Display of the yarn body and the actual clearing limit (thick places, NSL) with the forecasted cut values
The conventional way of optimizing the clearing limits is checking the existing ones by looking at the
yarn test results and entering the new ones manually based on the customers own experience. However this procedure is time consuming, especially for a new user, and needs some experience.
With the USTER QUANTUM 3, we have a very useful and smart tool to find the right starting point
for the new clearing limits. The Smart Limit function proposes a starting point for the clearing limits
based on the yarn body and also provides a cut forecast to facilitate faster setup of clearing limits.
Fig. 3-20 shows the selection of the optimum clearing curve for thick places. For a few seconds or
minutes the yarn runs with a pre-defined clearing curve (default value). After this period the operator
can see the yarn body on the screen. Now the clearing curve can be optimized either by moving the
clearing curve up or down. The setting can be fixed by pressing the confirm button.
USTER QUANTUM 3
3.11
Fig. 3-19
Fig. 3-20
After pressing the Smart Limit key, a small window with the two appropriate keys to adapt and optimize the smart limit for NSL thick places appears. The Smart Limit has been developed to propose a
starting point for the clearing limits by pressing one button. This proposal can be altered by open and
close keys to optimize the settings according to the individual quality requirements and productivity.
Every change of setting will automatically initiate a new calculation of the cut forecast. It is recommended to use the Smart Limit function after a minimum of 30 km of yarn has already been wound.
Of course all settings recommended by smart limit can also be altered manually. Even in this case the
new cut forecast is calculated.
=
The new setting point proposals
=
3.12
USTER QUANTUM 3
Besides the smart limit function, of course the thick places (NSL) classes are still a very powerful tool
where we can base our last decision.
Cuts/100km
Total yarn fault
counts /100 km in
this class
Fig. 3-22
NSLT yarn faults are displayed together with all other yarn faults of the machine, a group or a winding
position.
Fig. 3-23
USTER QUANTUM 3
3.13
3.6
Thin places, as long as they don't lead to yarn breaks, are only disturbing starting from a certain
length. The reason for disturbing thin places is a missing number of fibers in the cross-section as a
result of a non-optimal drawing process.
3.6.1
Classification matrix
As already described in the introduction of this application handbook, seldom-occurring yarn faults are
classified in the classification matrix of the USTER CLASSIMAT. The thin places are shown in the
classification matrix, Fig. 3-24.
Fig. 3-24
3.7
Fig. 3-25
3.14
USTER QUANTUM 3
Fig. 3-26 shows a long thin place with the classification -32% and 65 cm. This classification point, as
shown in the classification matrix, is located outside the clearing limit (Fig. 3-26).
-32%
65 cm
Fig. 3-26
3.7.1
Example of a long thin place in the setting window of the control unit
Fig. 3-17 shows the clearing limit as shown in the setting window of the control unit. The USTER
QUANTUM 3 gives us the chance of determining our clearing limits by placing a maximum of 8 set
points T1 to T8. In Fig. 3-17, we can see 5 setting points (red rectangle) and the clearing limit for T
thin places. By this setting method the effects of a change of the parameters on the clearing limit can
be demonstrated directly.
As soon as we enter new values at set point, the next one will appear until we reach the 8th set point.
This means after we enter the values for T1, set point T2 will appear and it will continue the same
way.
USTER QUANTUM 3
3.15
Fig. 3-27
Set points have two parameters. These are: sensitivity (%) and reference length (cm).
Sensitivity
The sensitivity (%) is a parameter for the clearing limits of the corresponding fault channel. The sensitivity setting shifts the clearing limit from the zero line away (less sensitive) or towards zero (more
sensitive). (T1= -45%, Fig. 3-27).
Reference length
The reference length (cm) is a parameter for the clearing limits of the corresponding fault channel and
shifts the clearing limit to the right (less sensitive) or to the left (more sensitive) (T1 = 2.6 cm,
Fig. 3-27).
3.16
USTER QUANTUM 3
3.7.2
Fig. 3-28 shows the selection of the optimum clearing curve for thin places. For a few seconds or
minutes the yarn runs with an automatically selected clearing curve (default value). After this period
the operator can see the yarn body on the screen. Now the clearing curve can be optimized either by
moving the clearing curve up or down. The setting can be fixed by pressing the confirm button (,
Fig. 3-30).
Pressing
key presents
The yarn body.
Scatter plot of the cut faults and
remaining events.
Number of expected fault cuts /
100 km.
Red dots = cut yarn faults.
Green dots = remaining
events.
=Yarn body variation
=Yarn body
= Proposes the starting
point for the clearing limits based on
the yarn body.
Fig. 3-28
Display of the yarn body and the actual clearing limit (thin places, T) with the forecasted cut values.
With the USTER QUANTUM 3, the user has a very smart tool to find the right starting point for the
new clearing limits. The Smart Limit function proposes a starting point for the clearing limits based on
the yarn body and also provides a cut forecast to facilitate faster setup of clearing limits.
The setting of USTER QUANTUM 3 can be done simply in one step:
Fig. 3-29
USTER QUANTUM 3
Fig. 3-30
3.17
After pressing the smart limit key, a small window with the two appropriate keys to adapt and optimize
the smart limit for T thin places appears. The Smart Limit has been developed to propose a starting
point for the clearing limits by pressing one button. This proposal can be altered by open and close
keys to optimize the settings according the individual quality requirements and productivity. Every
change of setting will automatically initiate a new calculation of the cut forecast. It is recommended to
use the Smart Limit function after a minimum of 30 km of yarn has already been wound (Fig. 3-29 and
Fig. 3-30).
Of course all settings recommended by smart limit can also be altered manually. Even in this case the
new cut forecast is calculated automatically.
Fig. 3-31
Besides the smart limit function, of course the thin place (T) classification is still a very powerful tool
where we can verify our last decision.
Cuts/100km
Total yarn fault
counts /100 km in
this class
Fig. 3-32
3.18
USTER QUANTUM 3
3.8
3.8.1
Thick places
In Fig. 3-33, we see the ring spinning areas of faults and their descriptions.
Ring Spinning Areas of Faults
Description
S1 Spun in fly waste
S2 Loose fly
S3 Long collections of fly
waste
Fig. 3-33
USTER QUANTUM 3
3.19
Description
S2 Loose fly
This refers to free fibers which
are collected by the yarn at a
position after the front roller and,
in most cases, are only spun-in
at one end.
3.20
USTER QUANTUM 3
Description
S5 Pushed-together collections
of fly
These are faults resulting from
fibers which are held back, and
occur primarily at the ring traveler.
S7 Crackers
This is due to extra long fibers
which disturb the drafting process and, for a short instant of
time, stop the passage of the
yarn.
In Fig. 3-34 to Fig. 3-43, there are various examples of thick place faults resulting from the spinning
process. Thick places in a woven fabric are given in Fig. 3-34 to Fig. 3-35. Here we can see a spun-in
fly failure (Table 3-1). This refers to free fibers which fall into the drafting elements or onto the roving
which is being fed into the drawing unit and are then twisted into the yarn along their entire length.
USTER QUANTUM 3
3.21
Fig. 3-34
Fig. 3-35
Fig. 3-36 to Fig. 3-38 show a red colored, 100% polyester T-shirt. Unless examined closely, the fault
would go unnoticed. However, we have discovered a disturbing thick place fault in the following
zoomed pictures (Fig. 3-37 and Fig. 3-38).
Fig. 3-36
Fig. 3-37
Fig. 3-38
In Fig. 3-39 Fig. 3-40, a pair of 100% cotton jeans is shown as an example. We can see the long nonperiodic thick places in the weft yarn in the zoomed picture.
3.22
USTER QUANTUM 3
There are two disturbing thick places in the white area (Fig. 3-40).
Fig. 3-39
Fig. 3-40
Fig. 3-41 to Fig. 3-43 show ladies pants, produced from 100% cotton, OE rotor yarn. In the previous
example (Fig. 3-39 and Fig. 3-40) the weft yarn has a long non-periodic thick place. But in the example in Fig. 3-41, the warp yarn has a long non-periodic thick place which can easily be noticed. In Fig.
3-42 and Fig. 3-43, the fault is magnified and indicated by an arrow.
Fig. 3-41
Fig. 3-42
USTER QUANTUM 3
Fig. 3-43
3.23
3.8.2
In Table 3-2 and Table 3-3 the origin of the faults related to seldom-occurring events / thick places is
given. Possible reasons and preventive measures to avoid such faults are explained and various
USTER tools for improvement are presented.
SELDOM-OCCURRING EVENTS / Thick Places
Origin of Faults
Drawframe
Comber
Roving frame
Spun-in fly waste from roving and spinning / Reduce flies in mill
Improper draft distributions in drawing, roving, and spinning
Wrong twist level in the roving
Tension problems at roving frame
Improper top roller pressure on roving frame
Winding machine
Table 3-2 Preventive measures and tools for the management of seldom-occurring events / thick places
3.24
USTER QUANTUM 3
Improvement
Adjustment of autolevellers
Table 3-3 Preventive measures and tools for the management of seldom-occurring events / thick places
3.8.3
Thin places
Fig. 3-44 to Fig. 3-46 show two examples of thin places in knitted fabrics. Long thin places in yarns in
the knitted fabric result in a severe defect. As illustrated in Fig. 3-45, the weak spots in the yarn gave
in after five washing cycles and caused holes in the fabrics.
Fig. 3-44
Long thin places in yarns in the knitted fabric result in a severe defect
Fig. 3-45
Fig. 3-46 shows a T-shirt with thin places. Although produced from 100 % combed cotton yarn, the
thin places show up as horizontal lines.
USTER QUANTUM 3
3.25
Fig. 3-46
Fig. 3-47 and Fig. 3-48 show a T-shirt with two horizontal lines, produced from 100% carded cotton
yarn. These lines, indicated by two black arrows, were produced by a yarn with a smaller diameter
(long thin places) than the normal yarn which has then caused thin places in the T-shirt.
Fig. 3-47
3.26
Fig. 3-48
USTER QUANTUM 3
3.8.4
In Table 3-4 and Table 3-5, the origin of the faults related to seldom-occurring events / thin places is
given. Possible reasons and preventive measures to avoid such faults are explained and various
USTER tools for improvement are presented.
SELDOM-OCCURRING EVENTS / Thin Places
Origin of Faults
Possible Reasons
Drawing frame
Roving frame
Winding
Table 3-4 Preventive measures and tools for the management of seldom-occurring events / thin places
Improvement
Adjustment of autolevellers
Table 3-5 Preventive measures and tools for the management of seldom-occurring events / thin places
USTER QUANTUM 3
3.27
3.28
USTER QUANTUM 3
Count variations
Count variations
4.1
Introduction
Deviations of the yarn count within a yarn lot lead to high costs for complaints. The fact that the faulty
yarn deviates from the nominal count can cause quality problems in the end product. The reasons for
count variations are diverse:
Peeled-off or uneven rovings can lead to significant count deviations within a bobbin
This demands a reliable monitoring of the yarn count on one side, but also its precise setting, which is
in accordance with the quality requirements of the yarn. This can be done in many ways. In the following, two possibilities are described:
The C-channel monitors the yarn count in the start-up phase after the splicing process. During
this phase, mainly bobbins with the wrong count are registered, and the winding position must be
stopped with the corresponding alarm functions. After the start-up phase, the C-channel is not active anymore. This procedure allows the choice of very sensitive settings, which are adjusted to
the special circumstances of the start-up phase of the winding position.
The CC-channel monitors the yarn count over the whole winding process. It is also possible to
monitor very long yarn faults with the CC-channel dependent on the choice of the settings.
4.2
The "yarn body" represents the nominal yarn with its tolerable, frequent yarn faults. Yarn body is a
new yarn characteristic, and we know from the experience so far that the yarn body changes according to the raw material and the spinning process. By analyzing the shape of the yarn bodies out of
different raw material varieties and process changes, we can discover patterns, and build up references. Based on the references, the operator can identify changes. The yarn body becomes always
wider in the direction of the short yarn events, e.g. short faults occur more frequently. On the contrary,
the yarn body becomes smaller in the direction of the long yarn events.
The USTER QUANTUM 3 interprets and displays the yarn characteristics with the help of the yarn
body. The yarn body is a great tool to help finding the optimum clearing limits for thick places (NSL),
thin places (T), yarn count deviations (C) and (CC).
The yarn body for CC is composed of two parts:
USTER QUANTUM 3
4.1
Count variations
Fig. 4-1
The vertical scale represents the yarn mass or diameter increase and decrease, and the horizontal
axis represents the fault length in meter.
Fig. 4-2 represents the yarn body for CC-fault. In Fig. 4-2 the green shaded area represents the yarn
body for medium and long-term variations (2 to 12 m).
Fig. 4-2
Yarn body display for medium and long-term variations (CC faults), defined from 2 to 12 m
The vertical scale represents the yarn mass or diameter increase and decrease, and the horizontal
axis represents the faults length in meter.
Since both dark and light green areas together constitute the yarn body, it is recommended that the
clearing curve should not touch the yarn body. If the clearing limit is laid within these green areas, the
cuts will increase significantly and the productivity will drop.
4.2
USTER QUANTUM 3
Count variations
4.3
Count deviations
4.3.1
The pre-condition for an exact monitoring of yarn count deviations is the correct determination of the
nominal yarn count. With the command "Start article" the parameters of C and CC are switched to a
less sensitive fixed value in order to avoid wrong cuts during the calibration process. After the start-up
of the winding position, each sensor determines the mean value for the running yarn and forwards it
to the Central Clearing Unit. The Central Clearing Unit (CCU) calculates the mean value from all the
transmitted values and sends it back to the sensors.
4.3.2
Deviations of the yarn count within a yarn lot lead to high costs for complaints. The fact that the faulty
yarn deviates over several meters or even longer from the nominal count can cause quality problems
in the end product.
This demands a reliable monitoring of the yarn count on one side, but also its precise setting, which is
in accordance with the quality requirements of the yarn.
Fig. 4-3 shows the possibilities for yarn fault monitoring, if the fault channels N, S, L, C and CC are
active.
Fig. 4-3
USTER QUANTUM 3
4.3
Count variations
4.3.3
Objective
The recognition of count deviations after the splicing process must be carried out very quickly, before
too much yarn is wound on the cone. The pre-conditions during the start-up phase are not always
perfect for a very sensitive monitoring. Therefore the monitoring must be carried out over a certain
yarn length, in order to avoid wrong cuts. All modern winding machines are able to remove detected
count deviations by setting a reference length on the clearer.
Count variations in the start-up phase must be monitored with the C-channel. The thresholds for the
clearer are set with the following parameters:
Reference length
The choice of the thresholds depends on different factors and must be adjusted to the conditions of
the mill:
Function
With each start-up, the C-channel monitors the yarn over the set reference length. The sensor
measures the mean value over this length. If the mean value exceeds the above limits, a cut follows.
Yarn suction after a C-cut / Machines with fault-related yarn suction
Up-to-date winding machines provide measurable, fault-related yarn suction. The sensor transmits the
length of a Cp or Cm cut to the processor of each individual winding position and determines the
length to be sucked-off.
As deviations from the nominal count can be calculated more precisely over a larger reference length
it is recommended to choose the cut length on machines with a fault related yarn suction as long as
possible. However, one has to pay attention that no back-windings occur during the suctioning of the
yarn. In practice, lengths of 6 to 8 meters proved to show the best results.
For very critical applications lengths of 12 to 20 m are recommended.
4.4
USTER QUANTUM 3
Count variations
4.3.4
Objective
The reasons for deviations from the yarn count are numerous and vary from mill to mill. In the
end product, such events are only disturbing because of their length.
By the draft, a faulty deviation can consists of several short, subsequent deviations, which are
only disturbing as a whole in the end product.
The recording of count variations and very long yarn faults takes place in the CC-channel, even when
they are interrupted by normal pieces of yarn. The yarn is monitored with two independent clearing
limits. The parameters for the clearer are given with the following settings:
CCp sensitivity setting for the monitoring of mass and diameter increases
CCm sensitivity setting for the monitoring of mass and diameter decreases
Reference length is set for different length classes between 2.0 and 12.0 meters
Function
In contrast to the C-channel, the CC-channel is active over the whole winding length. Therefore, a
different kind of signal evaluation is applied. A mean value is continuously calculated. Short drops of
the yarn count have only a minor effect on the total result of the continuous mean value. If the continuous mean value exceeds the above set sensitivity, a CC-cut is triggered.
Fig. 4-4
USTER QUANTUM 3
4.5
Count variations
4.4
C and CC settings
The C-channel monitors the yarn count in the start-up phase after the splicing process. After the startup phase, the C-channel is not active anymore. As already known from USTER QUANTUM 2, the Cchannel can be set for one reference length and a plus (Cp) and minus (Cm) limit.
The CC-channel monitors the yarn count during the whole winding process. Depending on the setting
long yarn faults with a small mass or diameter increase can be detected. This new CC-channel is able
to detect and remove count variations at different cut length between 2 m and 12 m.
For the CC-channel a smart limit proposal is available to find a good setting taking the variation of the
current production into consideration.
Fig. 4-5
4.4.1
Fig. 4-6
Display of CC setting. Smart limits available for length classes from 2 12 meters.
The C-channel monitors the yarn count in the start-up phase after the splicing process. After the startup phase, the C-channel is not active anymore.
In the example of Fig. 4-7 the Cp (plus) setting is 10% and the Cm (minus) setting is -10%. The reference length (C) is 6 m.
4.6
USTER QUANTUM 3
Count variations
Pressing
key presents
Fig. 4-7
Fig. 4-8
Yarn Ne 40, cotton 100%, combed, compact, capacitive sensor, 1010 km. Too short reference
length (2m) adjustment and too many cuts. It is recommended changing the reference length to
6m or 8m
USTER QUANTUM 3
4.7
Count variations
Fig. 4-9
4.4.2
Fig. 4-10 Yarn Ne 24, cotton 100%, carded, capacitive sensor, 3067.9 km.
Close settings, reference length is 10 m.
The CC-channel monitors the yarn count during the whole winding process. Depending on the setting,
long yarn faults with a small mass or diameter increase can be detected.
This new CC-channel is able to detect and remove count variations at different cut lengths between
2 m and 12 m. The setting points are:
The lines between the set points represent the clearing limit.
Fig. 4-11 shows the yarn body and the actual clearing limit for CC. For a few seconds or minutes the
yarn runs with an automatically selected clearing curve (default value). After this period the operator
can see the yarn body on the screen.
4.8
USTER QUANTUM 3
Count variations
Pressing
key presents
The yarn body.
Scatter plot of the cut
Number of cuts / 100 km.
Clearing limit
Red dots = cut yarn faults.
=Yarn body variation
=Yarn body
= Proposes the starting
point for the clearing limits based on
the yarn body.
Fig. 4-11
By pressing Smart Limit function a proposed starting point for the CC settings will be selected. According to the need of the customer this proposal can be accepted or modified with the smart limit
function or manually.
Fig. 4-12
After pressing the Smart Limit key, a small window with the two appropriate keys to adapt and optimize the smart limit for CC appears. The Smart Limit has been developed to propose a starting point
for the clearing limits by pressing one button. This proposal can be altered by up and down keys to
optimize the settings according to the individual quality requirements and productivity. It is recommended to use the Smart Limit function after a minimum of 30 km of yarn has already been wound.
USTER QUANTUM 3
4.9
Count variations
Of course all settings recommended by smart limit can also be altered manually.
As soon as the button at the smart limit window is pressed, the yarn body and scatter plot is displayed
on the setting page.
=
The new setting point proposals
= Smart Limit 1, step less sensitive.
= Smart Limit 1, step more
sensitive.
= Show yarn body and
scatter plot
= confirm and activate optimized clearing limit.
= cancel all modifications
Fig. 4-14
C and CC faults are displayed together with all other yarn faults of the machine, a group or a winding
position.
Fig. 4-15
4.10
USTER QUANTUM 3
Count variations
Fig. 4-16
Fig. 4-17
Frequent medium-term deviation of the count. Analysis of the spinning process required.
USTER QUANTUM 3
4.11
Count variations
Fig. 4-19
4.5
Yarn Ne 12, cotton 100%, carded, weaving, capacitive sensor, 771 km.
High number of count deviations within
the range of 2 to 12 m, 8,3 + 2,6 = 10,9
per 100 km.
Fig. 4-20 Yarn Ne 16, cotton 100%, carded, weaving, optical sensor, 492 km.
Low number of count deviations within the
range of 2 to 12 m, 4,1 + 2,0 = 6,1 per
100 m.
The determination of the setting parameters for the yarn count deviation monitoring must be carried
out very carefully. Different aids are at disposal.
4.5.1
As described before, the mean value of the yarn is determined from the single winding positions and
is detectable as the ADMV-value at the Control Clearing Unit. This means, this value presents the
100% - value of the yarn. This value can also be used for the calculation of deviations between bobbins. The ADMV takes factors like the material or the relative humidity already into account.
It is possible to calculate the count deviation in percent according to the following formula:
Formula 1:
Mass deviation( %) =
ADMV =
4.12
Yarn mean value / value which is generated by the sensor as an electrical signal when
inserting a yarn in the measuring slot.
USTER QUANTUM 3
Count variations
Article A:
Ne 30
ADMV: 776
Article B:
Ne 20
ADMV: 1204,2
Mass deviation( %) =
This means, that the difference between Ne 30 and Ne 20, measured with the capacitive sensor, results in a mass increase of 54,6%.
Article A:
Ne 30
ADMV: 4578,4
Article B:
Ne 20
ADMV: 5513,6
Diameter deviation( %) =
This means, that the difference between Ne 30 and Ne 20, measured with the optical sensor, results
in a diameter increase of 20%.
The percentage differences are limits. They should only be used as a guideline for the C- and CCsettings. Experience has shown that a certain tolerance must be taken into account. This means, the
selected settings should be lower than the calculated values.
4.5.2
Formula 2:
Mass deviation( %) =
USTER QUANTUM 3
4.13
Count variations
Yarn material
Factors
Relative humidity
0,86
80%
0,77
65%
0,69
50%
0,62
65%
Polypropylen, Polyethylene
0,56
65%
Polyester
0,50
65%
Polyvinylchloride
0,45
65%
Table 4-1
Example 3: Article A made out of Polyester is mixed up with article B made out of cotton
Yarn A: 20 tex: 20 x factor 0,5 = 10
Yarn B: 20 tex: 20 x factor 0,77 = 15,4
Mass deviation =
15,4 10
100% = + 54%
10
Example 4: Article A made out of cotton is mixed up with article B made out of Polyamide
Yarn A: 27, 8 tex: 27,8 x factor 0,77 = 21,4
Yarn B: 23,8 tex: 23,8 x factor 0,62 = 14,8
Mass deviation( %) =
14,8 21,4
100% = 31%
21,4
If the wrong bobbins deviate from the nominal yarn with respect to yarn material and yarn count, then
the mass deviation has to be calculated according to formula 3:
4.14
USTER QUANTUM 3
Count variations
Example 5: Article A made out of cotton (20 tex) is mixed up with blended yarn B PES/CO
67/33% (19,2 tex)
Yarn A:
Yarn B:
Mass deviation( %) =
11,3 15,4
100% = 27%
15,4
In order to compensate the variation of the yarn count, the channels C and CC should be set to an
about 5% more sensitive value than the calculated value.
4.5.3
As the iMH-O measures the yarn diameter, the count deviations must be converted in differences of
the yarn count. This can be done quite easily with the aid of the USTER Calculator (see section
4.5.5).
Conversion of the mass deviation to diameter deviations with the help of the USTER Calculator.
BA
8,33
100% =
100% = 25%
A
33,3
BA
+8,33
100% =
100% = + 33%
A
25
USTER QUANTUM 3
4.15
Count variations
4.5.4
The following diagram can only be used for the calculation of count variations when the capacitive
measuring head is used.
%
-5
+5
130
Nm/Nec
+10
+15
+20
+25
+30
+35
+40
+45
+50
120
110
100
90
80
70
60
50
40
30
20
10
A
10
Fig. 4-21
20
30
40
50
60
70
80
90
100
110
Nm/Nec
120
130
140
Determination of the mass deviation of yarns made out of the same material, but with a different
count
Fig. 4-21 shows two examples for the calculation of mixed-up bobbins:
Example 1: article A, Ne 68 is mixed with yarn B, Ne 80 deviation = -15%
Example 2: article A, Ne 50 is mixed with yarn B, Ne 40 deviation = +25%
When this calculation is carried out in tex, the values A and B must be reversed.
4.16
USTER QUANTUM 3
Count variations
4.5.5
Relationship between the mass and diameter deviation with the USTER Calculator
In this section, only the relationship between the mass and diameter deviations will be explained,
which can be calculated with the aid of the USTER Calculator. Scales and of the calculator serve
for this purpose.
Fig. 4-22
Depending on the measuring method and the unit which is used, the sliding tongue must be adjusted.
Example from Fig. 4-22: A mass deviation of 50% (7) corresponds to a diameter increase of only
about 22% (7).
Determination of the yarn count deviation with the USTER Calculator
For the setting of the C- and the CC-channel, the value, which a wrong yarn must deviate in order to
be recognized, must be entered in percent.
Example:
1. First, the correct yarn count must be set with the vertical line of the Calculator. In case of Fig.
4-23, it is Nm 20 and 50 tex, respectively.
2. Furthermore, depending on the measuring method (capacitive or optical) the sliding tongue of the
Calculator must be moved so that the tongue for the spun yarn is on the "0" mark.
USTER QUANTUM 3
4.17
Count variations
Fig. 4-23
3. If a wrong yarn with the count Nm 18,5 (54 tex) should be detected, the sliding tongue must be set
on this count (see Fig. 4-24).
4. Then, in the middle of the Calculator (area marked red), the corresponding deviation in percent
can be read on the scale. In this case, Fig. 4-24, for the optical sensor it is 4%, for the capacitive
sensor it is 8%. The same procedure must be carried out for negative deviations.
Fig. 4-24
4.6
For the choice of the right setting of the C- and CC-channel, the scatter plot serves as a helpful tool.
The scatter plot shows the unevenness of a yarn, even for longer yarn pieces, very well.
For the correct setting of the channels it is necessary to know which faults were defined as not tolerable by customers. It is also necessary to know the possibilities of the winding machine regarding the
setting of the suction length.
4.18
USTER QUANTUM 3
Count variations
From all this information, the settings for the clearer can be derived. An example for a correct setting
is explained in the following:
A spinning mill produces three different cotton yarns: Ne 20, Ne 30 and Ne 40. It is possible with a
normal unevenness of yarns to distinguish mixed up bobbins of these 3 yarn counts.
The setting of outlier or mixed-up bobbins is:
iMH-C
Cp: +24%
Cm: -20%
Reference length: min. 2 m or adjusted to the winding machine type
iMH-O
Cp: +12%
Cm: -10%
Reference length: min. 2 m or adjusted to the winding machine type
Due to the normal unevenness of a cotton yarn, it can be predicted that a more sensitive setting of
Cp/Cm can lead to unjustified cuts. It can also be said that the detection of counts anywhere between
Ne 20, Ne 30 and Ne 40 (e.g. Ne 24 out of a Ne 20) cannot be guaranteed anymore.
Rule of thumb for iMH-C:
The setting for the C-channel with a reference length of 2 to 4 m should not be set more sensitive
than the CVm of the yarn.
Rule of thumb for iMH-O:
The setting for the C-channel with a reference length of 2 to 4 m should not be set more sensitive
than 70% of the CVm of the yarn.
4.7
4.7.1
Bobbins with different yarn counts can be accidentally mixed up during yarn production, or there can
be count deviations within a cone. These count deviations can cause long stripes in the fabrics which
are visible to the naked eye.
In this example, we have knitted ten rows of reference yarn (Nec 30, 20 tex) and ten rows of a finer
yarn (Nec 34, 17,5 tex) spun from the rovings produced by using the same cotton blend, using the
ring spinning method. We can observe horizontal dark and light colored lines in both the grey (Fig.
4-25 and Fig. 4-26) and the dyed samples (Fig. 4-27 and Fig. 4-28). These horizontal lines are the
result of yarn count differences. There is also a difference between the diameter 2D values of these
two yarns (Table 4-2).
USTER QUANTUM 3
4.19
Count variations
Reference
Yarn
Count
(Ne)
Twist
1/m
Twist
direction
CVm
%
Thin 50%
Thick
+50%
Neps
+200%
2D
mm
CV2D
(8mm)
D (abs)
3
g/cm
30
830
12.7
0.5
34.5
66
4.6
0.22
9.6
0.5
61
29
71
73
22
34
883
13.5
6.0
52.5
90
4.5
0.20
10.3
0.5
77
>95
82
77
25
USP07
Wrong count
USP07
Table 4-2
18
27
= Optically measured diameter with the USTER TESTER 5 / Measurement of the yarn diameter with 2 light beams of 90 degrees
Fig. 4-25
4.20
Fig. 4-26
USTER QUANTUM 3
Count variations
Fig. 4-27
Reference fabric
Fig. 4-28
In a similar trial, we have used ten rows of a coarser yarn (Nec 26, 22,5 tex) and ten rows of reference yarn (Nec 30, 20 tex) and produced knitted fabric samples. Again in both the grey and the dyed
samples, we can observe horizontal dark and light colored lines. As mentioned previously, these horizontal lines are the result of yarn count differences. There is also a difference between 2D-diameter
values of these two yarns (Table 4-3). The pictures are not shown here, as the appearance of the
previous sample (with finer yarn) and this one are very similar.
Reference
Yarn
Count
(Ne)
Twist
1/m
Twist
direction
CVm
%
Thin
-50%
Thick
+50%
30
830
12.7
0.5
61
29
12.0
50
USP07
Wrong count
26
770
USP07
Table 4-3
Neps
+200%
2D
mm
CV2D
(8mm)
D (abs)
3
g/cm
34.5
66
4.6
0.22
9.6
0.5
71
73
22
0.0
22.0
32.5
4.9
<5
60
54
32
18
0.24
9.5
0.5
27
In another example, we have knitted 10 rows of reference yarn (Nec 36, 16,5 tex) and 10 rows of a
coarser yarn (Nec 30, 20 tex) spun from the rovings produced by using the same cotton blend.
USTER QUANTUM 3
4.21
Count variations
Then the knitted fabrics were dyed and T-shirt samples were produced. In the fabric and the T-shirt
sample, we can observe horizontal dark and light colored lines (Fig. 4-29 to Fig. 4-32). These horizontal lines are the result of yarn count difference (Table 4-4). Both yarns have the same evenness, but
as a result of different counts the diameter is different.
Reference
Yarn
Count
(Ne)
CVm
%
Thin
-50%
Thick
+50%
Neps
+200%
2D
mm
CV2D
(8mm)
D (abs)
3
g/cm
36
12.6
0.6
33.1
71.7
5.2
0.20
9.6
0.5
48
19
61
65
76
12.6
0.90
33.8
52.3
5.6
50
32
62
52
90
USP07
Wrong count
USP07
30
Table 4-4
Fig. 4-29
Reference T-shirt
Fig. 4-31
Reference fabric
4.22
Fig. 4-30
Fig. 4-32
40
0.23
9.8
0.5
55
USTER QUANTUM 3
Count variations
4.7.2
In Table 4-5 and Table 4-6, the origin of faults related to long-term mass variations is given. Possible
reasons and preventive measures to avoid such faults are explained and various USTER tools for
improvement are presented.
Yarn Count Variation
Origin of Faults
Drawing frame
Roving frame
Table 4-5
Preventive measures and tools for the management of long-term mass variations
Improvement
Constant quality control of sliver and yarn quality with the USTER
TESTER
Preventive measures and tools for the management of long-term mass variations
USTER QUANTUM 3
4.23
4.24
Count variations
USTER QUANTUM 3
Splice Clearing
5.
Splice Clearing
5.1
Introduction
A splice, also called yarn joint, has the purpose to join two ends of a yarn as a result of yarn fault removal on OE rotor and winding machines and bobbin changes during the winding process. This
means: when a detected fault is eliminated, the resulting yarn ends are pieced together by an automatic splicing device [1]. In the past, it was common practice to knot yarns together, but the knots
were a source of weakness and could also lead to problems in subsequent processes. Nowadays,
yarns are spliced using mechanical splicers, air-jet splicers, water-jet splicers, thermo-splicers, etc.
which produce a joint that is usually at least 70% of the strength of the mean yarn strength, and generally less than 130% of the thickness of the parent yarn. The splice efficiency is used as a measure
of the spliced part of the yarn, expressed as percentage strength of the reference yarn. The adoption
of splicing has greatly reduced problems in weaving, knitting, and dyeing [2].
A yarn must have a certain minimum tensile strength and a minimum elongation in order to stand up
to the processes subsequent to spinning. This is also and especially valid for splices that join together
two ends of a yarn. Since an average count ring-spun yarn can have more than 100 splices over a
length of 100 km, it is important to monitor the parameters of the splices carefully.
Besides the quality aspect that needs to be fulfilled by the yarn, its processing quality depends to a
certain extent also on the quality of the splices. Today, approximately one splice per kilometer has to
be expected in a cone. Considering the costs for a yarn break in knitting, warping, sizing or weaving,
the splices play an important role in this respect as well. The number of splices must be kept at a low
level, but the potential weak places must have the highest strength possible. This is only possible by
checking the strength of the splices regularly by means of an instrument.
5.2
The USTER QUANTUM 3 interprets and displays the splice characteristics with the help of a scatter
plot. It is the graphic representation of the thickness and length within a classification matrix. Each
splice is marked with one dot. The vertical scale represents the yarn mass or diameter increase and
decrease of a splice and the horizontal axis represents the splice length in cm. Fig. 5-1 shows a scatter plot with splices as seen by the USTER QUANTUM 3, with all the splice recorded (green dots),
the actual clearing limit and the area of the disturbing splices (red dots) which exceed the maximum
and minimum admissible splices.
The scatter plots are used to visualize the optimum clearing limits for both the Splice Clearing
(Jp/Jm), and for such events the graphical display of a scatter plot matches the demands of the
customers best. The scatter plot for Splice Clearing (Jp/Jm) represents the classified splices. The
USTER QUANTUM 3 classifies the thickest (Jp, Fig. 5-1, red circle) and thinnest (Jm, Fig. 5-1, blue
circle) event for every splice and show them on the scatter plot. The active clearing limit of the Jp
splice clearing limit is highlighted with red color on the setting page (Jp = joint, positive).
USTER QUANTUM 3
5.1
Splice Clearing
Fig. 5-1
In the display main menu, it is possible to display either scatter plot of splices alone (Fig. 5-2) or together with the scatter plot of disturbing thick and thick places (NSLT) (Fig. 5-3). Fig. 5-3 shows a
regular distribution of splices (dark green dots) together with the scatter plot of the thick and thick
places (light green dots). This combined scatter plot is a very helpful tool to show the localization and
the distribution of splices compared to the remaining thick and thin places in the yarn. With the help of
this combined graph, it is very easy to compare the splices to the natural events in the yarn and to
avoid unnecessary splices because it makes no sense to replace a small fault by a bigger splice.
Fig. 5-2
Fig. 5-3
The scatter plot of splices demonstrates the performance of the splicer and shows the position of the
outliers.
5.2
USTER QUANTUM 3
Splice Clearing
Fig. 5-4
Fig. 5-5
Fig. 5-6
Fig. 5-7
Splices beyond the clearing curves (red dots) have to be repeated. The scatter plots show the population of the splices. Based on the scatter plot it is easy to recognize the outliers and to set the clearing
curve for splices.
5.3
5.3.1
Splices
Visual appearance
Splices are almost invisible in contrast to knots which used to be yarn joints in the past. Various investigations have shown that the strength of the splices is critical in order to obtain a suitable splice in
terms of size, a compromise may need to be reached between splice strength and appearance. A well
spliced joint has a mass which is 20 to 30% higher than the yarn over a length of approximately 15 to
80 mm, and an average strength of around 80% of the mean yarn strength [1]. The variation of
strength should also be low. Fig. 5-8 shows pictures of several splices.
USTER QUANTUM 3
5.3
Splice Clearing
Fig. 5-8
5.3.2
Practical example
In a spinning mill the splices of 20 positions of a winding machine were tested. On each position, five
splices were tested. The yarn type was Ne 30, carded, 100% cotton. Fig. 5-9 and Fig. 5-10 show the
results of this trial. The blue dots indicate the test results of the splices, whereas the colored lines
show the test results (minimum, maximum and average values) of the same yarn without a splice
measured also on the USTER ZWEIGLE SPLICE TESTER as the reference (ten measurements of
the reference yarn). The minimum breaking force of the reference yarn was 222 cN, the average
breaking force was 261 cN and the maximum breaking force was 302 cN. In regard to the elongation,
the reference yarn had a minimum breaking elongation of 3.95%, an average breaking elongation of
4.66% and a maximum breaking elongation of 5.28% (Fig. 5-10).
400
350
300
Force [cN]
250
200
150
100
50
0
0
10
15
20
25
Force of splices
Fig. 5-9
5.4
30
35
40
45
Minimum Reference
50
55
60
65
70
Maximum Reference
75
80
85
90
95 100
Average Reference
Breaking force of splices, ring-spun yarn, compared with the mean strength of the yarn
USTER QUANTUM 3
Splice Clearing
10
9
8
Elongation [%]
7
6
5
4
3
2
1
0
0
10
15
20
25
Elongation splice
Fig. 5-10
30
35
40
45
50
Minimum Reference
55
60
65
70
Maximum Reference
75
80
85
90
95 100
Average Reference
Splice
Strength [cN]
261
200
9.91
23.0
Elongation [%]
4.66
4.87
10.16
16.88
Yarn type
Table 5-1
Out of this data, the following conclusions can be drawn. The splices only reach an average breaking
force of 76% compared to the regular (reference) yarn. As a rule of thumb, the strength of a splice
should reach at least 70% of the strength compared of a regular yarn. The breaking elongation, on the
other hand, improved slightly. Regarding the variation of the strength and the variation of the elongation it can be observed that it is much higher compared to the reference yarn. This is an important
quality parameter, as the high variation of the breaking force will lead to problems later on in subsequent processing. The lowermost breaking force of a splice was measured at 83 cN, and the strongest splice was measured with 295 cN. This is a huge difference that must be put under control.
Therefore, it is recommended to check the splice mechanism of this winding machine and to modify
the settings in order to reach higher strength values and lower variations from winding position to
winding position.
USTER QUANTUM 3
5.5
Splice Clearing
5.3.3
For a satisfactory splice, the two yarn ends have first to be prepared to make them properly tapered.
Also, the fibers must be adequately separated and paralleled so that they are capable of intermingling
when the splice is made. Fig. 5-11 illustrates the basic principle of the splicing process [1 and 2]:
Time 1: Positioning of the yarns and cutting the unwanted yarn ends: The winding process was
stopped in order to cut out the fault. The ends of the yarn are now parallel and face opposite directions. The scissors are ready to cut the unwanted yarn ends after the two yarns have been laid in
place.
Time 2: Conditioning the yarn ends: The clamps grasp the yarn at the appropriate places before the
main splicing procedure begins. The free ends of the two yarns are sucked into end-conditioning nozzles and air blasts are provided to condition them before joining.
Time 3: Forming loops to retract the yarn ends: Splicing is carried out after the two conditioned yarn
ends are laid inside the splicing chamber so they are parallel, facing opposite directions and appropriately spaced without the tips of the conditioned ends protruding. The both lengths are drawn back
until there is a certain length of overlap of the untwisted ends within the splicing chamber.
Time 4: Splicing ends: A pulse of compressed air is injected through the nozzles into the chamber; the
air blast intermingles the fibers and then causes the newly made joint to rotate to produce false twist.
Time 5: Removing spliced yarn. The yarn is then removed from the splicer and the winding process
continues.
Fig. 5-11
5.6
USTER QUANTUM 3
Splice Clearing
Fig. 5-12 [1] shows the twist directions and twist distribution during the splicing operation. The splicing
chamber in Fig. 5-12 (a) designed for use Z-twist yarns. The twist in the splice gives the joint a similar
appearance to that of the parent yarn and also strengthens the joint.
When the splice occurs, the ends have to be in the proper relative positions. In order to avoid a thick
splice, it is necessary to taper then ends to be spliced so that the joint is not obvious. In Fig. 5-12 (b),
the tapered ends are misplaced to give a thin spot. This is an undesirable weak spot. When the yarns
overlapped two much, there would be a thick spot and two undesirable splice-tails (Fig. 5-12 (c)).
These tails are mostly the subject of customer complaints during the knitting and weaving process.
The splicer should be set to avoid these tails, sometimes at the expense of a slight loss in splice
strength [2].
Fig. 5-12
5.3.4
Wet Splicing
The USTER QUANTUM 3 optical clearer can be used with wet splicer without any restrictions. The
capacitive clearer can be used with restrictions depending on the amount of water sprayed. Please
contact USTER for support.
For the capacitive clearer the combination with Foreign Matter option, i.e. either C15/F30 or C20/F30,
is required. There is a special setting for these clearers (Fig. 5-13) and the splice will be cleared optically and needs an optical setting.
USTER QUANTUM 3
5.7
Splice Clearing
Fig. 5-13
5.4
Wet splice
The USTER QUANTUM offers a unique feature, which is the splice classification. Each splice is
measured, classified, and marked with a green or red square in the scatter plot depending on the
splice settings. Thus, it is possible to check every winding position of a winding machine in order to
see if the splices fulfill the requirements with regard to the appearance (Fig. 5-14).
Fig. 5-14
Meaning of the red rectangles: The size of the splice or mass increase has exceeded the set splice
limits. The splice formation has to be repeated. The USTER QUANTUM 3 classifies the thickest (Jp)
and thinnest (Jm) event for every splice.
5.8
USTER QUANTUM 3
Splice Clearing
The splice channel J checks the yarn joint when passing the clearer just after it has been made by the
splicer device. The evaluation of J is similar to the NSLT thick and thin places evaluations. Splice
check Jp /Jm detects yarn joints which are too thick or too thin.
5.5
5.5.1
Fig. 5-15 shows the clearing limit as shown in the setting window of the Control Clearing Unit. The
USTER QUANTUM 3 allows the determination of the splice clearing limits by placing a maximum of
8 set points Jp1 to Jp8 /Jm1 to Jm8. In Fig. 5-15, we can see 5 setting points (red rectangle) and the
clearing limit for splices. By this setting method the effects of a change of the parameters on the clearing limit can be demonstrated directly.
As soon as we enter new values at set point, the next set point will appear until we reach the 8th set
point. This means after we enter the values for Jp1 (or Jm1), set point Jp2 (or Jm2) will appear and it
will continue the same way.
Fig. 5-15
Clearing limits on the screen of the Control Clearing Unit, manual entry
Set points have two parameters. These are: sensitivity (%) and reference length (cm).
Sensitivity
The sensitivity (%) is a parameter for the clearing limits of the corresponding fault channel. The sensitivity setting shifts the clearing limit upwards (less sensitive) or downwards (more sensitive,
Jp1 = 300%, Fig. 5-15).
USTER QUANTUM 3
5.9
Splice Clearing
Reference length
The reference length (cm) is a parameter for the clearing limits of the corresponding fault channel and
shifts the clearing limit to the right (less sensitive) or to the left (more sensitive, Jp1 = 0.6 cm, Fig.
5-15).
5.5.2
With the USTER QUANTUM 3 splice clearing became much easier. A smart possibility offered by
the system is to synchronize the splice settings to the thick and thin place (NSLT) settings to avoid
bad splices being passed. The splice clearing curve could be selected ideally as same as the NSLT
clearing limits.
Similar to the yarn body, after running only a few kilometers of yarn, the first impression of the scatter
plot and the events will appear. In order to see the scatter plot, the user should press the scatter plot
key (Fig. 5-16). Besides the scatter plot, also the scatter plot of the cut faults and remaining events,
and the number of expected fault cuts per 100 km together with the used setting limits will appear
directly on the same setting page (Fig. 5-16). It is recommended to have at least 100 splices before
making any fine tuning in the splice clearings settings.
Pressing
key presents
Fig. 5-16
For highest quality requirements the Jp, Jm setting can even be set up to 5 to 10% below the NSLT
clearing limit (red circle). Good splices set the Jp splice clearing curve below the NSL thick places
clearing curve (more sensitive setting) and on the contrary bad splices set the Jp splice clearing curve
above the NSL thick places clearing curve (less sensitive setting, Fig. 5-16). The same rule is also
valid for Jm splice clearing curve; there the Jm clearing curve will be set below or above the T thin
places clearing curve according to the good or bad results. If this will result in too many Jp or Jm cuts
then the rogue splicers should be identified and fixed. F and PP faults are also detected during splice
check (Fig. 5-17).
5.10
USTER QUANTUM 3
Splice Clearing
Fig. 5-17
Splices are displayed together with all the other yarn faults of the machine, of a group or of a winding
position. It can be switched from absolute values to values per 100 km.
Fig. 5-18
USTER QUANTUM 3
5.11
Splice Clearing
Recommendations:
The new setting possibilities will help to ensure that the splice should always be better than the removed yarn fault. Depending on the mechanical settings of the splicer, we recommend to start with
the splice adjusted to the thick place (NSL) and thin place (T) limits. For high quality requirements we
also can use a setting closer than the clearing limits. This depends on the accepted Jp/Jm cut level /
100 km and of course of the splice quality possible.
Splices are displayed together with all the other yarn faults of the machine, of a group or of a winding
position (Fig. 5-19, red rectangle). In Fig. 5-19, the splice failure ratio (JR) has also been shown (Blue
rectangle). Splice failure ratio (JR) measures the number of cut joints compared to the passed ones. It
is the relation between total splices and splice cuts (Jp+Jm). In this example, the splice failure ratio is
equal to 3.4.
Fig. 5-19
In order to find rogue splicers, the user should check the machine summary report to find the bad
splicer. In the following example it is winding position no. 9 with a splice failure ratio of 33.3%. The
mean value is 12.44% (Fig. 5-20).
5.12
USTER QUANTUM 3
Splice Clearing
Fig. 5-20
5.6
The upper yarn feature avoids that a double threat is accidentally taken from the package above the
clearer (Please consult Chapter 11).
Settings (Fig. 5-21):
For capacitive clearers:
80%
60%
Fig. 5-21
USTER QUANTUM 3
5.13
Splice Clearing
5.7
5.7.1
The number of splices depends on the selected number of cuts to eliminate disturbing faults and the
number of joints necessary to process bobbins into a cone.
There are experience values available for yarn clearers on winding machines to understand the replacement of disturbing faults by splices. The relationship between the bobbin size, the number of
cuts and the yarn count is explained in Fig. 5-22. This figure shows the number of splices required if
the yarn clearer cuts 20 disturbing thick and thin places, 20 colored foreign fibers and 2 polypropylene
fibers.
No. of splices
per 100 km
140
92g
120
100
57g
80
40g
60
Bobbin changes
Polypropylene fibers
40
0
6
100
Fig. 5-22
12
50
20
30
30
20
60
10
120 Nec
5 tex
The average yarn mass of a fine yarn bobbin is 40 g. The mass of a bobbin in the medium count
range is approximately 57 g and 92 g within the coarse count range. Fig. 5-22 shows that the number
of splices required per 100 km also depends on the count and the weight of the bobbin.
As already mentioned, the disturbing yarn faults have to be eliminated on the winding machine and
replaced by a splice. The splice, however, should no longer be disturbing for the human eye. Therefore, the splice can be checked by the yarn clearer (Fig. 23) and should be below the clearing curve.
5.14
USTER QUANTUM 3
Splice Clearing
Fig. 23
5.7.2
It is not only the number of splices which needs our attention, but also the mean time between two
splices. If we are not careful in selecting the optimum clearing curve, the efficiency of the winding machine may collapse.
Table 5-2 shows the conditions on a winding machine when processing a 100% cotton yarn, Nec 30,
carded, winding speed 1400 m/min. Figures per 100 km of yarn.
Bobbin changes
20
21
18
Polypropylene fibers
63
1.13 min
Table 5-2
Mean time between two
splices
The total run time of the machine to produce a yarn length of 100 km is 71.4 min at a winding speed
of 1400 m. With a total number of 63 splices, the mean time between 2 splices is only 1.13 minutes.
With a higher number of cuts, the mean time between splices would drop below one minute. This,
however, can be considered as a critical limit. Therefore, it is beneficial for the mill to select the clearing curves carefully for disturbing thick places, thin places and foreign fibers.
USTER QUANTUM 3
5.15
Splice Clearing
5.7.3
Field test
The USTER QUANTUM 3 has to fulfill more and more tasks. On one hand the spinning mill has to
eliminate disturbing thin places, thick places, colored foreign fibers and polypropylene fibers and has
to replace them by a splice. In addition, the splicer of the winding machine has to produce splices at
the end of each bobbin. On the other hand the clearer should not influence the efficiency of the winding machine too much. The following is a study to demonstrate the critical cut rates of a clearer by
means of the mean time between splices MTBS.
Conditions:
Yarn Ne 30 (20 tex), yarn weight per bobbin 57 g, yarn length per bobbin 2850 m
Winding speeds: 800 / 1000 / 1200 / 1400 / 1600 m/min
Number of splices according to Table 5-3.
Reasons for splices
Conditions
1
Bobbin changes
34
34
34
34
34
34
34
34
10
20
30
40
50
60
70
80
10
20
30
40
50
60
70
80
Polypropylene fibers
Number of splices
63
83
103
133
153
173
193
213
Table 5-3
Winding speed
Winding time
1
800 m/min
125 min/100 km
2.08
1.51
1.21
0.94
0.82
0.72
0.65
0.59
1000 m/min
100 min/100 km
1.59
1.20
0.97
0.75
0.65
0.58
0.52
0.47
1200 m/min
83 min/100 km
1.32
1.00
0.81
0.62
0.54
0.48
0.43
0.39
1400 m/min
71.4 min/100 km
1.13
0.86
0.69
0.54
0.47
0.41
0.37
0.34
1600 m/min
62.5 min/100 km
0.99
0.75
0.61
0.47
0.41
0.36
0.32
0.29
Table 5-4
5.16
USTER QUANTUM 3
Splice Clearing
Fig. 5-24
Reading example, Fig. 5-24: At condition 2 the mean time between splices already drops below 1
minute if the yarn speed exceeds 1200 m/min.
5.7.4
The adjustment of the clearing limits is not only improving the quality level of the yarn. But in all cases
the clearer should only remove the disturbing faults. The result is: optimum quality with less number of
cuts and splices. By only making the right cuts one can optimize quality and productivity.
It has been proven that the performance of the clearer (amount of cuts) is responsible for changing
drastically the winding machine productivity. In Fig. 5-25, the relationship between the productivity on
winding machines and splices can be seen. The red line is for yarn count Nec 50 and the blue line is
for yarn count Nec 30. Fig. 5-25 shows that 70 splices per 100 km means a productivity level of 79%
for yarn count Nec 30 and a productivity level of 81% for yarn count Nec 50. Speed: 1400 m/min.
USTER QUANTUM 3
5.17
Splice Clearing
Count
[tex]
Bobbin
weight
[g]
Fault cuts
[1/100km]
Bobbin
changes
[1/100km]
Winding
time for
100 km
without
splices
[min]
Formation
of a splice
[min]
Bobbin
change
duration
[min]
Total
duration
for fault
elimination [min]
Total
duration for
bobbin
changes
[min]
Total
duration
for stops
[m]
Winding
efficiency
[%]
1400
12 tex
(Ne 50)
60
20
20
71,43
0,18
0,22
3,6
4,40
8,0
88,8
1400
12 tex
(Ne 50)
60
70
20
71,43
0,18
0,22
12,6
4,40
17,0
76,2
1400
20 tex
(Ne 30)
60
20
33,3
71,43
0,18
0,22
3,6
7,33
10,9
84,7
1400
20 tex
(Ne 30)
60
70
33,3
71,43
0,18
0,22
12,6
7,33
19,9
72,1
Table 5-5
Fig. 5-25
5.18
Relationship between yarn clearing and productivity: splices and winding machine efficiency
USTER QUANTUM 3
6.1
Introduction
Periodic yarn faults are thick places, which always occur with the same distance to each other. Such
faults are caused in the spinning process, when yarn guiding elements are defective. An eccentric
front roller of the ring spinning machine leads to a periodic fault with a wavelength of 8 cm, because
the diameter of these rollers are 1 inch or 2,54 cm, and such a roller always causes faulty drafts in the
draw-box within the same time intervals.
The size of each individual fault is mostly not disturbing. But as a series of yarn faults, they can very
well be disturbing.
Disturbing patterns on a taper board due to periodic yarn faults can be seen in Fig. 6-1.
Fig. 6-1
The USTER QUANTUM 3 has a new periodic faults channel (PF), and with minimal settings and by
using only two parameters, the system can determine periodic faults of all wavelengths in parallel.
Fig. 6-2
USTER QUANTUM 3
6.1
6.2
On an automatic winding machine, the yarn speed is not constant. The yarn speed depends on the
position of the yarn during the reversal movement on the drum. Therefore, the yarn signal of a strictly
periodic yarn fault does not appear as a strictly period fault in a spectrogram (Fig. 6-3), but it also influences some adjacent lines.
In order to detect such kind of periodic faults in bobbins on winding machines a new feature was introduced, called PF (Periodic Fault). Bobbins with periodic mass variations have to be ejected by the
winding machine, because such faults are present throughout the entire bobbin.
Fig. 6-3 shows graphically the difference of a strictly periodic fault in a spectrogram if the speed is not
constant.
Strictly-periodic faults
detected by the yarn
clearer if the yarn
speed is constant
Fig. 6-3
There is a more intensive effect of the drum on the variation of the periodicities in the short wavelength range.
6.3
In most cases, disturbing periodic faults are formed at the ring-spinning machine. Widely known are
defects caused by cuts and pressure marks on the front rollers. By this, the continuous distribution of
the fibers is disturbed, which results in thin and thick places. The size of the fault corresponds to an
alteration/shift of all fibers of about 30 50%. The fault length depends on the dimension of the defective machine part. The distance between the single events corresponds to the circumference of the
roller.
6.2
USTER QUANTUM 3
If a spinning position or the whole spinning frame is stopped and the pressure is not taken from the
top roller, it can lead to pressure marks on the top rollers after longer stops and thus to periodic defects in the yarn. The distance between the single events corresponds to the circumference of the
rollers.
Defective aprons of the drawbox also result in periodic yarn faults.
For regular ring spun yarns, the reasons are mostly pure mechanical problems, which lead to periodic
faults in the yarn. For compact yarns, the reasons can be found in the contamination with fibers and
dirt. This dirt can build up for an uncertain time, which makes it much more difficult to find the reasons. Therefore, the monitoring of periodic defects in compact yarns is essential.
6.4
Periodic yarn defects cannot be detected with the normal settings of a yarn clearer, as the size of
each individual fault lies far below the adequate clearing limits. With the USTER QUANTUM 3 such
periods can be detected with the Periodic Fault (PF) channel. This periodic fault option (PF) allows a
quick and easy way of setting, and the system can scan the yarn for periodic faults of all wavelengths
simultaneously.
6.4.1
The periodic yarn faults always occur with the same distance from each other as already mentioned.
The thick places which are created by the periodic alteration of the fibers in the cross-section, serve
as the threshold in the PF-option.
The recommended setting for FP (Periodic Faults) is:
Period regularity:
75%
Number of periods:
30
PF-Alarm:
3 per 1 km
For long periods (< 1 m) it is also possible to set 90% regularity and 15 events.
After reaching the given number of faults ("number of periods"), a cut follows or a PF-alarm is triggered.
USTER QUANTUM 3
6.3
Fig. 6-4
Fig. 6-5
When the value of the period regularity is 100%, then the channel will detect only strictly periodic yarn
faults after a certain distance (Fig. 6-5). A setting of 100% means the periodicity is absolute. However,
on the winding machine a defect is never strictly periodic as already mentioned due to the varying
yarn speed.
Fig. 6-6
6.4
USTER QUANTUM 3
The checking of the settings is only possible with a defective yarn. There is also the option to choose
a very sensitive setting, in order to make corrections according to the results. This is only possible
with the sensitivity settings.
For fault free yarn set 30 events and adjust the regularity until you get 0,1 0,2 cuts/100 km
Furthermore, it is recommended to produce a taper board with the defective yarn for a visual evaluation of the defect.
Fig. 6-7
The detection of periodic yarn faults is displayed together with all the other yarn faults of the machine,
a group or a winding position. All cuts and alarms are displayed in absolute and relative values.
Fig. 6-8
USTER QUANTUM 3
6.5
6
6.5
Moir
Fig. 6-9
Stripiness
Optimum distribution
Fault patterns
The fault pattern referred to as moir is the most frequent, whereas the pattern on the right hand side
is an exceptional case. Nearly all periodic faults result in an uneven appearance in the finished fabric.
The type of disturbance, whether it is in a woven or knitted fabric, depends mainly on the wave-length
of the fault. In this respect one differentiates between short, medium and long-term periodic mass
variations.
6.6
USTER QUANTUM 3
Reference
Yarn
Count
(Ne)
Twist
1/m
Twist
direction
CVm
%
Thin
-50%
Thick
+50%
30
830
12.7
0.5
61
29
17.5
118
>95
>95
USP07
Fault
30
830
USP07
Table 6-1
Neps
+200%
34.5
66
4.6
71
73
22
1030
151
4.7
>95
>95
30
2D
mm
0.22
CV
2D%
(8mm)
9.6
D (abs)
3
g/cm
0.5
18
0.22
13.1
0.5
28
The result of the defective top roller can also be seen as red peaks in the mass spectrogram (Fig.
6-11) and periodicities in the conical taper simulation (Fig. 6-1). Because of the periodicities in the
defective yarn, thick places can be observed as dark-colored, periodic areas in the grey and the dyed
samples Fig. 6-12 and Fig. 6-13).
Fig. 6-10 shows the spectrograms of the reference yarn.
Fig. 6-10
Fig. 6-11
Spectrogram of the defective yarn (defective top rollers) measured with the USTER TESTER
USTER QUANTUM 3
6.7
Fig. 6-12
Reference fabric
Fig. 6-13
Periodic thick places have more fibers in the cross-section and absorb more dyestuff. Therefore, such
thick places appear darker in the fabric.
6.5.1
In Table 6-2 and Table 6-3, the origin of the faults related to periodic mass variations is given. Possible reasons and preventive measures to avoid such faults are explained and various USTER tools
for improvement are presented.
PERIODIC MASS VARIATIONS
Origin of Faults
Possible Reasons
Comber, Drawframe,
Roving frame,
Table 6-2
6.8
USTER QUANTUM 3
Improvement
Use Periodic Faults option to separate bobbins with periodic mass variations
Monitor bobbins with periodic faults with the quality data software
Preventive measures and tools for the management of periodic mass variations
USTER QUANTUM 3
6.9
6.10
USTER QUANTUM 3
7.
7.1
Introduction
In the previous chapters we have dealt with seldom-occurring yarn faults which can be eliminated and
replaced by a splice. This chapter deals with frequent yarn faults which cannot be replaced by a splice
anymore. If frequent yarn faults exceed preset quality limits, the bobbin has to be ejected by the winding machine. Such yarns, if wound on a cone, would affect fabrics significantly (cloudy appearance,
to many thick places, thin places and neps, high hairiness, etc.).
Fig. 7-1
Fig. 7-2
In order to meet the increasing quality requirements for the products and to cope with the high production costs, yarn manufacturers have to optimize the individual production stages at shorter intervals today.
With the optimization, it is important to fulfill the quality requirements of the customers completely and
reliably. The reaction time for an optimization or the adjustments is an important factor. Any quality
which is higher than actually required will result in an unnecessary increase of the manufacturing
costs. Off-quality, however, leads to significant quality costs and to a loss of customers.
Uncompromising quality management in all production stages guarantees a constant quality of the
product and, at the same time, a cost optimization.
In order to react immediately to changes of the yarn quality, it is important to monitor the quality parameters during the production.
USTER QUANTUM 3
7.1
The determination of the frequent yarn faults is an option of the USTER QUANTUM 3 and consists
of:
class alarm
hairiness
Fig. 7-3
The values of the yarn evenness, of the hairiness and of the imperfections are important information
about the quality of a yarn. Through their results, it is possible to control the complete course of production. The analysis of the single value makes it possible to carry out countermeasures without any
time delay.
The following differences between the off-line measurement (laboratory) and the on-line measurement (production) must be considered:
Off-line measurement
The main purpose of the off-line measurement is the correct determination of the quality parameters.
The results are reproducible, as the measurement is always carried out under the same conditions, i.e. a standard climate, the same sensor, and with the same testing speeds.
The results can be used for comparison purposes, like e.g. the USTER STATISTICS.
7.2
USTER QUANTUM 3
On-line measurement
The main purpose of the on-line measurement is a 100% monitoring of the yarn and its quality
parameters.
The measurements are carried out with different sensors (measuring field width, capacitive or
optical).
The measurements are carried out on different machines. The environmental conditions such as
climate, yarn course, dust, fly, and temperature are not constant in the winding room.
If limits are exceeded, actions can be taken in order to remove the faulty yarn from the production
process.
The on-line monitoring of quality parameters cannot replace the off-line measurement, because different requirements have to be fulfilled.
This makes it clear, that the absolute values of the on-line measurement cannot be compared exactly
with those of the off-line measurement. However, the on-line measured deviations from the nominal
value match within certain tolerances with the measurements of the off-line tests.
With the USTER QUANTUM 3 all the features of a yarn, which determine its quality, can be measured individually. This delivers detailed information. Besides the values of the yarn evenness, the hairiness and the imperfections have to be taken into account. Practical tests have shown clearly, that
with a careful decision regarding the setting of alarms and the consequent tracking of fault reasons,
the quality level can be kept within narrow limits, and this can be realized without excessive costs.
In the following, different possibilities for the monitoring of the yarn structure are described. The setting of the alarms of the different monitoring possibilities must also be carried out. This is described in
chapter 7.6.
7.2
Yarn evenness
The coefficient of variation CV is a well-known value for the determination of the evenness of slivers,
rovings and yarns. Each process in a spinning mill contributes a part to the unevenness.
The continuous determination of the quality parameters guarantees that all spinning positions produce
the same quality. For the calculation of the yarn evenness CV, it is possible to select 2 measurements:
Continuous, over the whole bobbin length with selectable reference lengths or
When a preset limit is exceeded, the system can provide an alarm for the respective winding position
and another one for the mean value of a quality parameter derived from all winding positions.
USTER QUANTUM 3
7.3
7.2.1
The coefficient of variation is given in percent; it is a measure of the yarn unevenness and is defined
as follows:
CV =
s
100 %
x
Mass/
diameter
+s
-s
x
Length
Fig. 7-4
With the help of the coefficient of variation, CVm as well as CVd, winding positions which deviate with
respect to quality, can be monitored.
CVm = Coefficient of variation based on the measurement of the yarn mass (capacitive sensor)
CVd = Coefficient of variation based on the yarn diameter (optical sensor)
7.2.2
The reason for yarn irregularity is based on the fact that it is not possible for staple fiber yarns to keep
a constant number of fibers in the cross-section. Reasons can be divided into:
raw-material related faults, like e.g. the variation of the fiber length, fiber adhesion, short fiber content, stickiness
process-related faults, caused by defective machine parts, like draw-box defects or the kind of
roller coats
From these points it can be derived that the coefficient of variation is used as an efficient method for
quality and process monitoring.
In general it can be said: the lower the CV-value, the more even is the material and the more even it
will look in the end-product.
It is known, that the evenness is not constant over the whole bobbin length. It usually decreases from
the tip to the base of a bobbin. This circumstance has to be taken into account when evaluating the
setting of the alarm limits.
7.4
USTER QUANTUM 3
Fig. 7-5 to Fig. 7-7 show a mercerized cotton T-shirt. In the zoomed pictures (Fig. 7-6, Fig. 7-7) we
can observe an uneven appearance of the knitted fabric because of thin places and thick places even
though it is an expensive mercerized T-shirt.
Fig. 7-5
Fig. 7-6
7.2.3
Fig. 7-7
The CV mean value of the group (CV-MV) is determined from all winding positions. As it is based on a
large population, it does not show any erratic deviations. Erratic deviations can occur with individual
winding positions. The upper alarm limit CV-MV upper and the lower alarm limit CV-MV lower can
be set independent of each other. Compared to the CV of the winding position, this "alarm band" is
set to a relatively high sensitivity because a mean value CV-MV which exceeds preset limits is usually
an indication of serious problems (Fig. 7-8).
The CV-MV indicates important changes and trends of the yarn. In an initial test cycle, the settings of
this alarm band should not be selected too sensitive. After the CV mean value of the group has been
determined over a certain time span (e.g. one shift or several doffings), then the upper and lower
alarm limits can be set.
USTER QUANTUM 3
7.5
If the upper or lower alarm limits are exceeded, then this will be indicated by an alarm. After a period
of observation, the setting can then be adjusted according to the specific application. This is illustrated
by Fig. 7-8.
Fig. 7-8
7.2.4
Schematic representation of the deviation behavior of the CV mean value of the group
The mean of the CV of an entire machine (CV-MV) is used as a reference for the CV value of a single
winding position. The monitoring of the CV of the spinning position is carried out in relation to the current CV mean value of the machine. As with the CV-MV, an "alarm band" can be set for the CV-SP
value. The set value is effective in both the positive and the negative direction. If an alarm limit is exceeded, then this will be indicated by an alarm. Depending on the settings, the winding position can
be blocked.
Example:
The percentage deviation (CV-SP), which is defined as the alarm limit, is calculated by means of the
CV-MW, as shown in the following example, Fig. 7-9: With a CV-MV of 14% and an alarm limit of
20%, the effective range is between 11.2% and 16.8%. The deviation behavior of the CV of the single winding position is shown schematically in Fig. 7-9.
Fig. 7-9
7.6
USTER QUANTUM 3
7.2.5
Settings
In the window "Q-Parameter" of the Control Unit, the following settings can be adjusted:
Fig. 7-10
Reference length:
It is possible to set the reference length between 50 10'000 m. In winding, a reference length of 100
m has been accepted as the standard. This is a length which is necessary for a reliable CV-value.
However, the setting of the reference length also depends on the objective when monitoring the coefficient of variation.
USTER QUANTUM 3
7.7
Measurement:
The measurement can be carried out:
continuously
at bobbin change
The following winding machines provide a bobbin change signal. This means that the winding position
informs the clearer when a bobbin change is carried out:
Savio Orion
Savio Polar
The setting of an upper CV alarm limit which serves for the monitoring and detection of:
-
The setting of a lower CV alarm limit serves for monitoring and the detection of yarns, which have
too much twist caused by:
-
If the yarn evenness of a bobbin deviates from the spindle ALARM LIMIT, a CVp- or CVm alarm is
triggered. At the same time, this deviation from the mean value can be found on the window for "textile alarms" at the control unit.
If the information on the yarn evenness is desired only, there is the possibility to set the alarm limit,
but without selecting any actions. In this case, the number of alarms is indicated in the shift report.
If the alarm limit is set to 0, the monitoring of the alarms is inactive.
7.8
USTER QUANTUM 3
Action
If the unevenness CV of a winding position exceeds the upper or lower alarm limits, the sensor reacts
according to the selected alarm, setting column ACTION. An entry is made in the logbook in all cases.
There are four different possibilities:
register
cut
block
block +suck
If the action register is chosen, the measurement with a set limit serves only for data collection to
monitor the quality of the production. There will be no reaction on the winding position. The alarm will
be counted as Q Registration. If USTER QUANTUM EXPERT for winding is connected; the signal is
transferred to this data system for alarm purposes.
With the selection cut, a cut is triggered when a preset alarm limit is reached. The sensor will cut and
the alarm will be counted as a Q Cut. The faulty yarn will be removed from the cone with the maximum possible length of the winding position.
The action block can be recommended, if it is desired to take a bad bobbin out of the process. The
winding position will be blocked and the sensor lamp lights up. The alarm will be counted as Q Blocking. The behavior of the winding position depends on the machine type. For this, trained personnel
are necessary. Depending on the machine type, an automatic bobbin change is carried out or the
bobbin must be changed manually.
The action block + suck can be recommended, if it is desired to take a bad bobbin out of the process. The winding position will be blocked and the sensor lamp lights up. The alarm will be counted
as Q Blocking. The Reference length or evaluation length of the quality parameters CV, H or IP has a
fixed maximum length of 64 m if the action at alarm is set to "block + suck". After the blocked winding
position has been reset, 64 m yarn will be sucked off from the cone.
7.2.6
Fig. 7-11 shows the results of the CV-measurement of each winding position as well as the CV-mean
value of the group and the absolute CV-alarm at the control unit.
USTER QUANTUM 3
7.9
Fig. 7-11
SP UPPER LIMIT
The upper absolute CV-limit is calculated from the CV-mean value of the group and the set relative upper CV-alarm limit.
SP LOWER LIMIT
The lower absolute CV-limit is calculated from the CV-mean value of the group and the set relative lower CV-alarm limit.
If the CV of a winding position lies above or below the absolute SP ALARM LIMIT, a CVp- or CVmalarm is triggered.
7.3
Imperfections
"Imperfections" are frequent thick and thin places as well as neps, which are formed when processing
fibers into yarns. They can be raw material related as well as process related. The frequency and the
size of imperfections influence considerably the further processing and the quality of a yarn and thus
the textile fabric.
The frequency and the size of these events can provide information about the quality of a produced
yarn. Furthermore, the data serve for monitoring and the optimization of the processes in spinning
preparation.
Fig. 7-12 shows a T-shirt with a high number of thick places, thin places and neps under reflective
and transmitting light. It shows the irregularity caused by imperfections on the surface of the garment.
The reflective light shows particularly the amount of neps. The same garment shows particularly the
effect of the short thick places and thin places on the appearance of the fabric in transmitting light.
7.10
USTER QUANTUM 3
Fig. 7-12
7.3.1
Garment
Reflective light
Transmitting light
Definition of imperfections
Imperfections are divided in three fault groups and four classes. This can be seen in Table 7-1.
Fault group
Class
Neps
shorter than 4 mm
140%
200%
280%
400%
Thick place
35%
50%
70%
100%
Thin place
-30%
-40%
-50%
-60%
Table 7-1
USTER QUANTUM 3
7.11
Neps
Neps have an enormous influence on the appearance of a textile fabric. Neps are defined as follows:
"Dense tangle of intertwined fibers with a core of fibers or with seeds or seed coat fragment slightly
enclosed in fibers. Usually spherical. Diameter approximately 1 mm."
We differentiate between raw material-related and process-related neps.
Fig. 7-13
Fig. 7-13 shows an enlarged image of a knitted fabric made with a scanning electron microscope. It
shows the effect of these so-called shiny neps. The neps, which in part consist of dead and immature
fibers, have not absorbed any dyestuff at all. They remain in the fabric as small white spots. Seedcoat fragments, which also contain fibers, are also known as raw-material related neps.
Process-related neps
Process-related neps are actually produced in the opening/cleaning lines and in spinning preparation.
Due to the fact that cotton is being cleaned at very high speeds, this also results in a loss of quality.
The consequences of higher cleaning speeds are a higher content of short fibers and neps. The initial
increase of the number of neps occurs already during the ginning process, and additional neps are
produced in the cleaning lines of the spinning mills. Carding may result in a significant reduction in the
number of neps but, depending on the condition of the clothing, it also produces new neps.
The effect of an increased number of neps is becoming noticeable especially in fine knitted or woven
fabrics. An increased number of neps also causes problems while processing fabrics in the knitting
mill (breaking of needles, loops are not properly taken up, formation of holes).
7.12
USTER QUANTUM 3
7.3.2
Settings
The determination of the alarm limits requires some basic knowledge of statistics first, the mean value
of the number of imperfections over at least 10 producing winding positions has to be determined.
The mean value indicates the arithmetic mean of the single values. It is the sum of all single values,
divided by the number of the single values.
The standard deviation is the variation of single values and can be calculated according to the rules of
statistics. The standard deviation, therefore, is used for setting the alarm limits.
Fig. 7-14
Evaluation length
Setting: 100 m to 2000 m. After this length the alarm condition is checked and a new measurement
started. It is recommended to select an evaluation length of 1000 m.
Neps
The limit for neps of all classes can be set between 0 64000. If 0 is selected, the monitoring is inactive. For neps, the operator can select between several sensitivity levels.
USTER QUANTUM 3
7.13
Thick places
The limit for thick places can be set between 0 64000. If 0 is selected, the monitoring is inactive. For
thick places, the operator can select between several sensitivity levels.
Thin places
The limit for thin places can be set between 0 64000. If 0 is selected, the monitoring is inactive. For
thin places, the operator can select between several sensitivity levels.
Action
If the class limit is reached on a winding position, the sensor reacts according to the setting ACTION
at the ALARM window. An entry is made in the logbook in all cases. There are four possibilities:
register
cut
block
block +suck
If the action register is chosen, the measurement with a set limit serves only for data collection to
monitor the quality of the production. There will be no reaction on the winding position. The alarm will
be counted as Q Registration. If USTER QUANTUM EXPERT for winding is connected; the signal is
transferred to this data system for alarm purposes.
With the selection cut, a cut is triggered when a preset alarm limit is reached. The sensor will cut and
the alarm will be counted as a Q Cut. The faulty yarn will be removed from the cone with the maximum length of 64 meter. This setting should not be chosen, as a pure cut does not make much
sense.
The action block is recommended, if it is desired to take an off-quality bobbin out of the process. The
winding position will be blocked and the lamp of the sensor lights up. The alarm will be counted as Q
Blocking. The behavior of the winding position depends on the machine type. For this, trained personnel are necessary. Depending on the machine type, an automatic bobbin change is carried out or
the bobbin must be changed manually.
The action block + suck can be recommended, if it is desired to take an off-quality bobbin out of the
process. The winding position will be blocked and the lamp of the sensor lights up. The alarm will be
counted as Q Blocking. The reference length or evaluation length of the Q parameters CV, H or IP
has a fixed maximum length of 64 m if the action at alarm is set to "block + suck". After the blocked
winding position has been reset, 64 m yarn will be sucked off from the cone.
7.14
USTER QUANTUM 3
7.3.3
Fig. 7-15 displays the last measurement over the evaluation length with date and time of:
Fig. 7-15
The results of the sensitivity levels will be marked in color in case of set alarm limits for certain classes.
red
7.4
Class-Alarm
This alarm deals with yarn faults which are classified in the USTER CLASSIMAT matrix, Fig. 7-17.
If one wants to monitor repeatedly occurring yarn faults which are not disturbing as a single event but
as a group of faults the winding position can be stopped with the class-alarm. A single D1 fault might
not be disturbing, but a series of several D1 faults shortly after each other cannot be accepted in the
end product. With the setting of an alarm in this class, e.g. 3 faults per kilometer, the winding position
will be stopped when the alarm limit is reached. The bobbin must be removed by the personnel.
USTER QUANTUM 3
7.15
With the USTER QUANTUM 3 class-alarm, according to the USTER CLASSIMAT criteria, the user
has a tool which operates according to the same criteria as the USTER CLASSIMAT for the laboratory. Seldom-occurring yarn faults are detected, assessed and classified within the well-known CLASSIMAT matrix according to length and mass deviations.
This provides the user with complete information on the yarn quality and allows him to make a forecast for the subsequent process stages. Based on this information about the quality parameters, the
user can then apply that knowledge to specifically use the yarn according to the customer's requirement profile.
The yarn fault classification is carried out simultaneously at all winding positions according to the
USTER CLASSIMAT: Short thick places with a mass or diameter increase of at least 75%, 45 long
thick places with a mass or diameter increase of at least 30% and thin places with a mass or diameter
decrease of at least 20% are classified within the CLASSIMAT matrix in 45 thick and thin place classes. This allows the user to quickly identify any outlier winding positions. The CLASSIMAT matrix is
shown in the following Fig. 7-17.
Fig. 7-16
The user can select between displays of the detected yarn faults or of all remaining yarn faults. The
yarn fault classification is permanently active and cannot be switched off. In addition, there is the possibility of displaying the data of individual winding positions or the complete machine, which also can
be printed out via a function key.
7.4.1
Fig. 7-17 shows the fault channels of the CLASSIMAT matrix with the fault length (cm) and the fault
size (%).
7.16
USTER QUANTUM 3
Fig. 7-17
7.4.2
process related changes, i.e. worn-out machine parts, like e.g. card cloth, defect regulation of the
draw box, fly, dirty machines, etc.
The rising of yarn faults is an indicator for a negative change in the textile process, which has to be
looked at carefully.
7.4.3
Settings
Fig. 7-18
USTER QUANTUM 3
7.17
Evaluation length
It is possible to set the evaluation length between 1 6000 km per winding position. This means, that
the alarm condition is checked referred to this length. It is recommended to set the evaluation length
to 1 km.
Class
One out of 23 classes. It is possible to set limits for up to 5 classes.
Alarm limit
The alarm limit can be set between 0 and 64000 events until an alarm is triggered.
Action
If the alarm limit is reached on a winding position in one out of 5 classes, the iMK reacts according to
the setting ACTION at the ALARM window. An entry is made in the logbook in all cases. There are
three different action settings:
register
cut
block
If the action register is chosen, the measurement with a set limit serves only for data collection to
monitor the quality of the production. There will be no reaction on the winding position. The alarm will
be counted as Q Registration. If USTER QUANTUM EXPERT for winding is connected; the signal is
transferred to this data system for alarm purposes.
With the selection cut, a cut is triggered when a preset alarm limit is reached. The sensor will cut and
the alarm will be counted as a Q Cut. The faulty yarn will be removed from the cone with the maximum by the winding position supported length.
The action block can be recommended, if it is desired to take a bad bobbin out of the process. The
winding position will be blocked and the lamp of the sensor lights up. The alarm will be counted as Q
Blocking. The behavior of the winding position depends on the machine type. For this, trained personnel are necessary. Depending to the machine type, an automatic bobbin change is carried out or
the bobbin must be changed manually.
7.4.4
The class alarm can be triggered for the channels: N/S and L/T. It can be selected between the results of the machine, the group or individual winding positions. The results can be displayed absolute
or per 100 km.
7.18
USTER QUANTUM 3
In the upper part of the result window of the individual classes, the status of the measurement is displayed:
OK:
ALARM:
In the lower part of the result window, the overall number of events corresponding to the chosen reference length is given.
Fig. 7-19
The result of the class will be marked in color in case a set alarm limit was exceeded.
red
7.5
The tailored classes offer the possibility to define customer classes or group classes together for special purposes. It is also useful to inspect yarn faults and foreign fibers within the customized class.
The aim is to define tailored classes for NSL, T and FD (Fig. 7-20 and Fig. 7-21). The settings can be
done by defining sensitivity in % and cm of the upper right and lower left corner for the tailored class
for NSL, T or FD. In order to inspect faults within the tailored class the user should use the LED function of the sensor. The tailored class will be shown in the classification matrix of the related clearing
function.
The tailored classes offer the possibility to define custom classes or group classes together for special
purposes. Tailored classes are used only for information and will not influence the cut ratio. After
changing the tailored class, the data should be cleared (clear counters) otherwise the tailored class
values are mixed up with the former settings.
USTER QUANTUM 3
7.19
7.5.1
Settings
Fig. 7-20
Fig. 7-21
7.20
USTER QUANTUM 3
7.5.2
The tailored class will be shown in the classification matrix of the related clearing function (Fig. 7-22,
right side). Tailored class can be used for the LED function.
Fig. 7-22
Classification matrix at the Control Unit (at the Displays main menu)
To better understand defects Uster Technologies always recommends to put the fault on a black
board (disturbing thick and thin places) and on a white board (foreign fibers). To make this easier the
iMH-LED function and the display of defect length, percentage and classification can be displayed on
the event report on the CCU (Fig. 7-23). The iMH-LED is turned on, when a tailored class cut is triggered.
Fig. 7-23
USTER QUANTUM 3
7.21
7.6
On new winding machines, the textile alarms are shown on the man-machine interface of the machine. A reset of the textile alarm is carried out by the machine. Depending on the machine type, the
reset of the alarm is carried out at a bobbin change. By this, the alarm of the sensor is also deleted.
Especially by selecting the same reference length for different quality parameters, it can happen that
two different alarms are triggered at the same time. As an example the following event is described:
The yarn evenness and the hairiness are monitored over a reference length of 400 m. For both monitoring parameters, the respective limits are set and the action "block" is selected. It is possible, that an
off-limit bobbin shows a higher hairiness as well as a higher unevenness. In this case, both alarms
can be triggered, i.e. an alarm for CVp and an alarm for Hp.
7.7
Hairiness
Hairiness plays an important role in the textile industry. Hairiness variations in yarns can substantially
affect the appearance and the hand of woven and knitted fabrics. Furthermore, hairiness can be disturbing in subsequent processes.
With the introduction of compact spinning, the hairiness monitoring on the machine became more and
more a must. Since the hairiness of compact yarns is very low, it is important that bobbins which deviate in hairiness can be recognized immediately. Otherwise the fabrics have to be downgraded.
Statistical surveys (USTER STATISTICS) have shown that yarns have become more even. Therefore, variations of the quality characteristics of conventional yarns from bobbin to bobbin have become more disturbing than several years ago. This is also valid for the hairiness.
7.7.1
The oldest hairiness monitoring system represents the counting of the number of protruding fibers at a
distance of 3 mm from the yarn body. (Fig. 7-24).
Fig. 7-24
7.22
USTER QUANTUM 3
A testing method with high reproducibility was introduced in the market by Uster Technologies in 1988
with the USTER TESTER 3. The method is based on a dark field optics (Fig. 7-25 and Fig. 7-26).
Fig. 7-25
Fig. 7-26
Fig. 7-25 and Fig. 7-26 represent the hairiness of yarns from the point of view of the optical receiver.
The yarn body is dark, but all the loose and protruding fibers are bright and contribute to the hairiness
measurement. The light intensity along the yarn is permanently measured by the receiver. Since the
yarn body is dark, it does not contribute to the hairiness monitoring.
It is possible to evaluate hairiness and to calculate the absolute hairiness, the hairiness variation and
to print out a diagram and a spectrogram of hairiness with this measuring principle.
It could be proved in various interlaboratory trials that this measuring method is the most accurate
hairiness monitoring system in the industry. Uster Technologies has been publishing USTER STATISTICS for hairiness since 1989.
The conditions for the clearer are different. Therefore, a suitable solution had to be found, which produced comparable results, even with the limited space conditions which are available for the clearer.
Fig. 73 and Fig. 74 show a 100% cotton, yellow colored garment. In the zoomed picture (right) it is
obvious that the hairiness is rather high.
USTER QUANTUM 3
7.23
Fig. 7-27
Fig. 7-28
The following 100% bleached cotton T-shirt (Fig. 75 and Fig. 76) also shows excessive hairiness.
Fig. 7-29
Fig. 7-30
7.24
USTER QUANTUM 3
7.7.2
Settings
Fig. 7-31
Reference length
It is possible to set the reference length between 50 and 10000 m at the Control Unit. After the length
setting the alarm condition is checked and a new measurement is started. As already mentioned for
the monitoring of the yarn evenness, it is necessary to adapt the reference length to the respective
quality demands. Depending whether changes of the hairiness should be monitored or only registered, the reference length will be different.
USTER QUANTUM 3
7.25
Measurement
The measurement can be carried out:
continuously
at bobbin change
The following winding machines provide a bobbin change signal. This means that the winding position
transmits a trigger signal to the clearer, when a bobbin change is carried out:
Murata PC 21
Savio Orion
Savio Polar
0,1 20.0
0,1 20.0
0,1 20.0
0,1 20.0
Action
If the hairiness of a winding position is exceeded on one of the alarm limits, the sensor will react according to the setting ACTION at the ALARM window. There are four different possibilities:
register
cut
block
block +suck
If the action register is chosen, the measurement with a set limit serves only for data collection to
monitor the quality of the production. There will be no reaction on the winding position. The alarm will
be counted as Q Registration. If USTER QUANTUM EXPERT for winding is connected; the signal is
transferred to this data system for alarm purposes.
With the selection cut, a cut is triggered when a preset alarm limit is reached. The sensor will cut and
the alarm will be counted as a Q Cut. The faulty yarn will be removed from the cone with the maximum by the winding position supported length. This setting should not be chosen, as a pure cut does
not make much sense.
The action block can be recommended, if it is desired to take a bad bobbin out of the process. The
winding position will be blocked and the lamp of the sensor lights up. The alarm will be counted as Q
Blocking. The behavior of the winding position depends on the machine type. For this, trained personnel are necessary. Depending to the machine type, an automatic bobbin change is carried out or
the bobbin must be changed manually.
7.26
USTER QUANTUM 3
The action block + suck can be recommended, if it is desired to take a bad bobbin out of the process. The winding position will be blocked and the lamp of the sensor lights up. The alarm will be
counted as Q Blocking. The Reference length or evaluation length of the Q parameters CV, H or IP
has a fixed maximum length of 64 m if the action at alarm is set to "block + suck". After the blocked
winding position has been reset, 64 m yarn will be sucked off from the cone.
7.7.3
Fig. 7-32 shows the hairiness results per spinning position, the mean value of the hairiness per group
as well as the upper and lower alarm limit.
Fig. 7-32
Any hairiness value of a winding position that is above or below the absolute SP ALARM LIMIT will
trigger a Hp or Hm alarm. At the same time, it is possible to read the deviation from the mean value
out of the display for Textile Alarms.
As far as information on hairiness only is desired, there is the possibility to set the alarm limits without
selecting any actions. In this case, the number of events exceeding the limits is indicated in the shift
report.
USTER QUANTUM 3
7.27
7.7.4
Uster Technologies has investigated various aspects of hairiness in order to clarify the effect of hairiness variations on fabrics.
Fig. 7-33
It is obvious in Fig. 7-33 that the human eye can recognize hairiness differences of H = 1. The same
trials were carried out with a viscose yarn with the same result.
Investigations on hairiness variations on fabrics made out of compact yarns have shown that differences of H = 0,6 ... 0,7 could already be recognized .
7.7.5
The textile industry is aware of the fact that the hairiness on all the spinning positions must be kept
under control. Therefore, it is strongly required that the hairiness is measured on the machine so that
100% of the yarn is monitored. The following events have generated the need for such monitoring
systems:
Since 1988 a highly reproducible hairiness testing system is available with the USTER TESTERS
3 and 4. The experience with these systems and the consequences on fabrics have proven that
hairiness deviations of only H = 1 can be seen in the fabrics after dyeing. Therefore, hairiness variations have to be avoided.
7.28
USTER QUANTUM 3
Compact yarns have only very little hairiness. Therefore, compact yarns with only small deviations
can easily be recognized in the fabric. Contamination and defects in the compacting zone can
prevent the correct formation of compact yarns. This can lead to the production of a yarn with
"normal" hairiness, instead of a yarn with only a little hairiness. After dyeing, such hairiness variations become clearly visible.
7.7.6
The laboratory tests for hairiness can be regarded as benchmarks for the textile industry. The
USTER STATISTICS are also available for such tests.
Fig. 7-34 shows the correlation of the USTER off-line system with the on-line system. These tests
were carried out by installing the USTER on-line system in the thread-line of the USTER TESTER.
12,00
Com4 11.8Tex
10,00
Com4 11.8Tex
Com4 11.8Tex
Ring gek. 14.7Tex
8,00
Ring 24.6Tex
Ring 16.4Tex
6,00
Ring kard.19.7Tex
Ring 50%PES 29.5Tex
Com4 gek.7.7Tex
4,00
Com4 11.8Tex
Ring kard. 20Tex
2,00
14,00
12,00
10,00
8,00
6,00
4,00
2,00
0,00
0,00
Ring 100Tex
Hairiness
USTER
TESTER
5 4
TESTER
Hairiness
USTER
Fig. 7-34
The correlation between the off-line and the on-line measurement in Fig. 7-34 is very good. However,
practice has shown that such ideal conditions as shown in Fig. 7-34 are not always given on the winding machine. As already mentioned, there are many factors which influence a correlation with the
measurements in the laboratory. For this reason, as for the results of the yarn evenness, the absolute
values of the hairiness will not exactly correlate with the results in the laboratory. However, there is a
very good correlation regarding the relative deviations from the mean value.
USTER QUANTUM 3
7.29
It must be taken into account, that the winding machine increases the hairiness. This applies mainly
for the unwinding of the yarn from the bobbin with high speed, for yarn tensioners and deflection devices.
7.7.7
Hairiness characteristics within a bobbin or a package depend on the spinning system. The
knowledge of hairiness characteristics is important for comparison tests between the off-line and the
on-line systems for reaching high accuracy and reproducibility.
For conventional ring-spun yarns, the hairiness increases from the bobbin tip to the bobbin base. The
increase is in the order of about 10% (Fig. 7-35).
In comparison to ring-spun yarn, for compact yarns the increase of the hairiness from the bobbin tip to
the bobbin base only reaches about 2 to 4%.
The origin of these within-bobbin variations is the ring rail movement causing varying balloon sizes
and varying angles of the yarn at the ring traveler.
Fig. 7-35
Fig. 7-35 shows the hairiness variation within a cross-wound cone. In the case of ring-spun yarn, the
test was made after winding.
Since the conditions on the OE rotor spinning machine are the same at any time, there is also a constant hairiness throughout the package.
Therefore, if values of on-line systems have to be compared with off-line systems, it has to be taken
into consideration that the laboratory results represent only 400 m of yarn from the bobbin tip. For
comparison it is, therefore, recommended to measure the bobbin tip on the winding machine as well.
The USTER QUANTUM 3 allows this measurement for all winding machines which generate a bobbin change signal.
7.30
USTER QUANTUM 3
Fig. 7-36 shows the hairiness from the tip of the bobbin to the base, each test representing 400 m of
yarn. In Fig. 7-36, the bobbin tip is represented with blue color, the bobbin base in light red color.
5
4,8
4,6
4,4
4,2
4
1
10
Fig. 7-36
7.7.8
Practical examples
5.8
5.6
5.4
Hairiness H
5.2
4.8
4.6
4.4
4.2
4
1
21
41
61
81
101
121
141
161
Fig. 7-37
181
H-Mw
201
221
241
261
limit Hm - 0.7
281
301
321
341
361
381
401
421
441
Winding positions
limit Hp + 0.7
USTER QUANTUM 3
7.31
Abbreviations
H
H-MW
Limit Hp +0,7
= Positive limit (red) set to +0,7 with reference to the mean value
Limit Hm -0,7
= Negative limit (blue) set to 0,7 with reference to the mean value
3.4
3.3
3.2
3.1
Hairiness H
3.0
2.9
2.8
2.7
2.6
2.5
2.4
2.3
2.2
2.1
2.0
1
21
41
Fig. 7-38
61
H-MW
81
101
Hm-limit -0,5
121
141
Winding
positions
Hp-limit +0,5
Abbreviation:
H
= Hairiness
MW-group
Hm-limit 0,5
= Negative limit (blue) is set to 0,5 with reference to the mean value
Hp-limit +0,5
= Positive limit (red) is set to +0,5 with reference to the mean value
7.32
USTER QUANTUM 3
7.8
If the operator is interested in marking the alarmed bobbin in order to re-check them off-line in the
laboratory, he can select the "continuous printout". For this purpose, it is possible to print out the Qalarms by selecting the feature of the "continuous printout" at the Control Unit. After each stop, a
printout follows. This printout provides information to the operator about the alarm reason and the
deviation from the nominal value. This printout can be attached to the bobbin and further analyses of
the bobbin can be carried out in the laboratory.
7.9
Bobbins which exceed the selected limits for quality characteristics have to be ejected at the winding
machine. For this purpose, we have to discuss the characteristics which can be detected with a modern yarn clearer:
Unevenness
Hairiness
Excessive cuts
Frequent neps
Clusters of faults
In establishing a real quality management system, it is of utmost importance that selections made by
the yarn clearer with respect to quality characteristics can be verified in the laboratory.
The following examples to explain what this means.
Fig. 7-39 shows the determination of hairiness on the machine.
Hairiness
4.65
4.55
4.45
4.35
4.25
4.15
Fig. 7-39
12
15
18
21
24
27
30
33
Weeks
On-line monitoring of hairiness / Count: Nec 30, ring-spun yarn, cotton, combed
USTER QUANTUM 3
7.33
Fig. 7-40 shows the distribution of the hairiness on the winding machine. A selection criterion was set
to select the bobbins which exceed the warning limit.
Frequency
300
250
200
150
100
50
Hairiness
Fig. 7-40
4.66
and higher
4.58
4.51
4.43
4.27
4.35
4.12
4.20
4.04
3.96
3.89
3.81
3.73
3.65
3.58
3.50
3.42
3.34
3.27
3.11
3.19
3.03
2.96
2.88
2.80
On-line hairiness measurement / Count: Nec 40, ring-spun yarn, cotton, combed
Fig. 7-40 shows the distribution of the hairiness measured on a winding machine on 2500 bobbins. A
limit was set to separate and eject bobbins which will lead to visual disturbances in a fabric.
7.9.1
In the previous chapters, it was explained in detail how modern quality management tools can contribute to the improvement of the performance of a spinning mill. However, we identified one major
area where mill managers and quality managers still suffer. This is the area of outliers. Since one single thread in the warp on a weaving machine can downgrade the entire woven fabric, it is of utmost
interest to get rid of outliers.
An average ring spinning mill has a size of 20,000 to 30,000 spindles. In comparison with other industrial activities, the number of production positions in spinning mills is very high. Therefore, a well organized spinning mill will have a repair crew which permanently improves outliers among the production positions. The repair crew, however, needs input from the laboratory where systematic quality
analyses are made.
7.34
USTER QUANTUM 3
Fig. 7-41
The bobbins which are ejected by the winding machine are analyzed in the laboratory. Outliers are
brought back to the normal distribution.
The bobbins of individual spinning machines are marked to identify the production positions where the
ejected bobbins came from.
The ejected bobbins are brought to the textile laboratory, where the quality problems are evaluated.
The findings are listed on an instruction sheet for the repair crew. The intention to bring the outliers
back within the normal distribution range (Fig. 7-41).
The repair crew has to undertake the repair work at the machines (Fig. 7-42). Successful repairs are
reported back to the laboratory.
Fig. 7-42
Bobbins which are recognized as having tolerated quality characteristics will go back to the yarn
batch. The outlier bobbins will be handled as second-grade bobbins.
USTER QUANTUM 3
7.35
7.9.2
Laboratory
Marking of spindle
position
Fig. 7-43
Action plan
for repair crew
If the winding machine ejects a bobbin from this ring spinning machine, it is easy to find the spinning
position where the bobbin was produced.
Therefore, it is recommended, particularly in low cost countries, to designate the bobbins of one doff
and one machine every day. In a medium size spinning mill of 20000 to 30000 spindles it will last
approximately 20 to 30 day to check and trace back all the outlier bobbins in a mill.
Identification process:
The spinning mill establishes a test plan which ring spinning machine has to be tested at what
day.
All the bobbins of this machine are identified for one doff so that the laboratory operators know
where the ejected bobbin came from.
The production position which produced the ejected bobbin is entered into the action plan for the
maintenance and repair crew.
The maintenance and repair crew receives an action plan from the laboratory.
Fig. 7-44 shows part of an action plan for the maintenance and repair crew. The yellow part is filled in
by the laboratory staff. This part also has a column where the laboratory operators insert the expected
source of the fault.
The green part of the action plan is filled in by the repair crew. They also confirm if the expected
source proposed by the laboratory staff was correct. If the crew finds another fault, the technical problem is described in detail.
7.36
USTER QUANTUM 3
The action plan goes back to the laboratory the same day when all the actions are finished.
Machine
Spinning
position
Detection
in
laboratory
Expected
source
Source found
by repair crew
Action
taken
Time
for
repair
Signature
Date
14
RSM
231
Peak in
spectrogram
at 8 cm
Damage
on front
roller, ring
spinning
Contamination
of front roller
due to
honeydew
Cleaned
front roller
10 min
June 25,
2007
14
RSM
284
High
periodic
hairiness
Ring
traveller
Ring traveller
worn out
Replaced
ring
travellers
5 min
June 25,
2007
Periodicity at
28 m
Contamination of
drawbox of
finisher
drawframe
Same
Cleaned
drawbox of
finisher
drawframe
10 min
June 25,
2007
3
Finisher
drawframe
Fig. 7-44
The yarn monitoring system on the last machine in the spinning process
also has to check the quality characteristics.
USTER QUANTUM 3
7.37
7.9.3
The closed loop system was tested in the industry with considerable success. If the clearer really can
detect quality deviations from established benchmarks, it will also be possible for the quality specialists to trace back the yarn faults to the origin. The following are a few examples where faults could be
traced back to the ring spinning machine.
Examples 1 and 2
A bobbin was ejected by the automatic winding machine as an outlier, because the evenness (CVm)
was too high. In the laboratory the high evenness could be confirmed. Since the bobbin was identified
with the spinning position at which the yarn was produced, the repair crew found that the top roller of
the respective drawbox was contaminated with honeydew (Fig. 7-45).
Fig. 7-45
Honeydew deposit
Fig. 7-46
Defective apron
Another outlier bobbin was ejected at the winding machine because the number of S-faults was too
high. A check at the spinning machine could clarify that a defective apron with a hole has caused this
alarm at the yarn clearer (Fig. 7-46).
7.38
USTER QUANTUM 3
Examples 3 and 4
Another outlier bobbin was ejected because of a high number of S-faults. After having confirmed this
in the laboratoary as well, the check at the respective spindle at the ring spinning machine has shown
that the apron of the drawbox moved in the wrong direction, and, therefore, the joint was defective
(Fig. 7-47).
Fig. 7-47
Fig. 7-48
A bobbin was identified as outlier by the yarn clearer because the number of imperfections was too
high. The check at the ring spinning machine has shown an accumulation of fiber fragments at the
locations indicated by yellow arrows in Fig. 7-48.
7.9.4
There are some limitations on the winding machine to reach the same accuracy as spinners reach in
the laboratory. The reasons for these limitations are:
The yarn speed is not constant on a winding machine. Therefore, periodic mass variations cannot
be measured directly on the winding machine. Periodic events have to be measured by indirect
measurements such as the higher evenness or the frequent occurrence of thick and thin places.
However, in the laboratory the operator can measure the yarns at constant speed and, consequently, an accurate spectrogram can be determined. With this precise information of specific periodicities the textile laboratory can elaborate a detailed action plan.
The microclimate on the winding machine near the yarn clearer is given by various variables such
as the environmental conditions in the winding room, the heat produced by the winder, etc. In the
laboratory the environmental conditions are defined by international standards.
As a result of this it is strongly recommended to check the bobbins in the laboratory which are ejected
at the winding machine due to quality problems.
Table 7-2 is a recommended test procedure for a textile laboratory in a mill with 27000 spindles, cotton 100%, combed, count range Ne 30 to Ne 50.
USTER QUANTUM 3
7.39
Machine
No. of machines or
positions
Card
First drawframe
Comber
Finisher
drawframe
Roving frame
Ring frame
Winder **
Quality
characteristics
Test intervals
Test
speed
Test
length
Required
test time per
day *
12
Evenness
Diagram
Spectrogram
Variance-length
curve
2 per day
100
m/min
250 m
8 min
Evenness
Diagram
Spectrogram
Variance-length
curve
2 per day
100
m/min
250 m
8 min
12
Evenness
Diagram
Spectrogram
Variance-length
curve
2 per day
50 m/min
250 m
16 min
Evenness
Diagram
Spectrogram
Variance-length
curve
4 per day
50 m/min
250 m
32 min
600
Evenness
Diagram
Spectrogram
Variance-length
curve
5 roving
bobbins per
day
100
m/min
250 m
16 min
27000
Evenness
Diagram
Spectrogram
Imperfections
Hairiness
Yarn diameter
Density
Trash
800
m/min
1000 m
169 min
60 ejected
bobbins from
winding machine daily
800
m/min
1000 m
113 min
20 cones per
day
800
m/min
1000 m
39 min
600
Evenness
Diagram
Spectrogram
Imperfections
Hairiness
Yarn diameter
Density
Trash
10 bobbins
per machine
every third
day
(90 bobbins
daily)
401 min
Total
Table 7-2
*
**
Total test time required in the laboratory per day for this example
7.40
USTER QUANTUM 3
The total test time per day is equivalent to 401 minutes or 6 hours and 41 minutes. This indicates that
the tests can be managed in one shift.
The total test time is based on an average work load in the laboratory. However, the slivers of the
cards, drawframe, combers, etc., can also be measured at the same day.
As a measure for corrections at machines with non-identified bobbins we recommend to study the
action plan once per day, to check the analysis of the outlier bobbins, to walk along each machine
and to check the spinning positions.
7.9.5
Conclusion
Most of the spinning mills have an established quality management system based on sample testing.
With such a quality system, however, it may last year or more to get rid of outliers.
This paper describes a method with which outlier bobbins can permanently be separated on the winding machine with the help of yarn clearers and traced back to the faulty spinning position.
The method which is described in this paper also allows the daily elimination of outlier bobbins.
The described system is used by various mills with considerable success.
7.10
Yarn evenness (CV), hairiness and imperfections and their effect on the fabric
appearance
Card
Regular maintenance
Drawing
frame
Roving
frame
USTER QUANTUM 3
7.41
Improvement
Adjustment of autoleveller
Table 7-3
7.42
Preventive measures and tools for the management of random mass variations
USTER QUANTUM 3
Referencecompact yarn
Yarn
Count
(Ne)
Twist
1/m
Twist
direction
CVm
%
Thin
-50%
Thick
+50%
Neps
+200%
2D
mm
CV2D
(8mm)
D (abs)
3
g/cm
30
770
10.1
0.0
6.0
8.0
3.7
0.20
7.5
0.6
<5
<5
11
<5
62
10.5
1.0
12.0
19.0
4.0
51
23
80
USP07
Defectivecompact
yarn
30
770
USP07
<5
34
0.21
7.9
52
Thin -40%
Thin -50%
Thick +35%
Thick +50%
Neps +140
Neps +200
3.0
0.0
45.0
6.0
46.0
8.0
USP07
<5
<5
<5
11
<5
<5
Defective compact
yarn
13.0
1.0
76.0
12.0
100.0
19.0
24
51
34
23
Reference compact
yarn
USP07
Table 7-4
28
0.6
Yarn quality results, well maintained and badly maintained compact spinning machine
We made fabric simulations for these two yarns using the USTER TESTER 5 fabric simulation program and the results are given in Fig. 7-49 and Fig. 7-50. The increase in the number of the small
neps can be seen in the right hand picture. The neps (+200) are shown as white points and indicated
by white arrows.
USTER QUANTUM 3
7.43
Fig. 7-49
Fig. 7-50
In Table 7-5 the origin of faults related to imperfections is given. Possible reasons and preventive
measures to avoid such faults are explained and various USTER tools for improvement are presented.
YARN IMPERFECTIONS
Origin of Faults
Possible Reasons
Roving frame
7.44
USTER QUANTUM 3
YARN IMPERFECTIONS
Origin of Faults
Possible Reasons
Roller spacing
Condition and hardness of top cots
Eccentric or damaged front rolls (top or bottom)
Too coarse fiber
Wrong drafting zone settings
Bad conditions of top rollers
Bad operation of the overhead cleaner
Extreme air conditions
Neps
Raw material:
Length uniformity
Short fiber content
High micronaire variations
High level of neps
Improvement
Systematic quality control of sliver and yarn quality with USTER TEST
ER / imperfection counts and comparison with USTER STATISTICS
Use the imperfections block function form the Q DATA option and separate those bobbins with excessive counts
USTER QUANTUM 3
7.45
7.10.3 Reasons and measures to minimize excessive hairiness and hairiness variations
There are various reasons for the formation of excessive hairiness and hairiness variations. In this
section, some of these reasons will be explained with the help of pictures of the knitted samples and
their yarn quality results.
Reference
Yarn
Count
(Ne)
CVm
%
Thin
-50%
Thick
+50%
Neps
+200%
sh
2D
mm
CV
2D%
(8mm)
D (abs)
3
g/cm
36
12.6
0.6
33.1
71.7
5.2
1.30
0.20
9.6
0.5
48
19
61
65
76
>95
12.2
0.20
30.2
76.4
4.0
0.93
37
<5
57
67
<5
19
USP07
Compact
USP07
36
40
0.19
9.4
0.6
<5
Table 7-6
Fig. 7-51
Reference T-shirt
Fig. 7-52
Defective T-shirt
Fig. 7-53
Reference Fabric
Fig. 7-54
7.46
USTER QUANTUM 3
Less twist
The twist of the yarn has a decisive effect on the hairiness: the lower the twist, the higher the hairiness, and thus the hairiness decreases with increasing yarn twist. This correlation can be explained
by the fact that, in cases of a high twist, the number of protruding fibers decreases because most of
these fibers are embedded into the yarn body.
The spindles of the ring frame are driven by one or more belts which engage the whorls (pulleys) that
project from the bottom of the spindle. Slippage of the belts can lead to twist losses, which vary from
spindle to spindle. These variations can cause barr and stripping problems when the yarn is assembled into the finished fabric [2].
Eccentric rings/spindles
As is well-known, both eccentric spindles and rings can increase the hairiness of the yarn as well as
influence its strength and elongation, especially at high eccentricities. Additionally, the life of an eccentric spindle is shorter than a normal one and it has a higher noise level. An eccentric spindle, or a
displaced guide or ring, can also increase the end-breakage rate remarkably, because of the periodic
tension variation at each revolution.
In Table 7-7, the origin of faults related to excessive hairiness and hairiness variations is given. Possible reasons and preventive measures to avoid such faults are explained and various USTER tools
for improvement are presented.
EXCESSIVE HAIRINESS
Origin of Faults
Possible Reasons
Raw material
Fiber length
Length uniformity
Excessive short fiber content
Roving twist
Age and type of rings & ring travelers (ring spinning)
Spinning tension (ring spinning)
Yarn twist
Slipping spindle belts
Damaged pigtail guides
High winding speed
Condition of rings
Eccentricity of spindles & rings
Traveler changes
Full bobbin diameter
Yarn twist
Damaged or worn travelers
Separator slap
Improperly positioned or missing anti-balloon rings
Spindle speed
USTER QUANTUM 3
7.47
EXCESSIVE HAIRINESS
Origin of Faults
Possible Reasons
Spindle speed curve
Improper traveler weights
Damaged cots
Improperly centered pigtail guides
Variation of spinning climate
Improvement
Use quality data settings for hairiness to separate spinning bobbins with excessive hairiness
7.48
Preventive measures and tools for the management of excessive hairiness and hairiness variations
USTER QUANTUM 3
Foreign fibers
Foreign fibers
8.1
Introduction
Foreign fibers are one of the major problems in spinning mills. The global ITMF [3] survey on cotton
contamination in 2009 showed that, in the perception of spinners from around the world, contamination remains a serious problem. During the past 20 years the degree of significantly contaminated
cotton bales has been increasing steadily from 14% to 22%. Organic matter is still the main contaminant, followed by fabrics of cotton and plastic film, strings of jute and plastic [3]. These fibers can be
of different origin, character, structure or color. There are distinct benefits to early detection and removal of unwanted fibrous material, since subsequent processing stages open up and spread out
these foreign fibers. This can result in the contamination of many yarn packages [1]. Fabrics containing foreign fibers cannot be dyed homogeneously, and these fibers can cause many quality problems, especially after finishing [4]. Foreign fibers and materials adversely affect processing, produce
end breaks and also affect the dye uptake, fiber reflectance and the appearance of the final product
[2].
It is obvious that foreign matter in textile fabrics can no longer be accepted. Therefore, the fight
against foreign material in cotton has to cover all the areas where this type of contamination can occur.
Many foreign fiber problems are detected only after finishing, and the spinner is ultimately held responsible for the damage.
Therefore, the costs for such claims can be considerable, and provisions have to be made to absorb
such claims if the spinning mill does not have a quality management system to eliminate or minimize
the number of foreign fibers in yarns.
The following is a collection of experience with foreign matter removal systems prior and after the
card.
Fig. 8-1 and Fig. 8-2 show separated foreign material in cotton.
Fig. 8-1
USTER QUANTUM 3
Fig. 8-2
8.1
Foreign fibers
In Fig. 8-3 and Fig. 8-4 we can see the result of a large blue plastic part which was cut into individual
fibers by the card. As can be seen the cotton fibers are contaminated with blue colored plastic fibers.
The plastic fiber cluster (Fig. 8-3 and Fig. 8-4) will result in foreign fibers in yarns.
Fig. 8-3
Fig. 8-5
8.2
Fig. 8-4
USTER QUANTUM 3
Foreign fibers
8.2
Dense Area
Another new, innovative and unique feature of the USTER QUANTUM 3 is the Dense Area. The
dense area in the scatter plot (appearance versus length) is the display of the range where foreign
fibers are occurring very frequently but which can hardly be recognized in a fabric because they are
very small (Fig. 8-6). This display of the dense area helps the user to set a clearing limit easier with
an optimal balance between quality and productivity. The dense area depends on the raw material. If
a yarn is produced from cotton having a lot of foreign matter or vegetables, then the dense area will
be wider and a high number of cuts have to be expected.
Similar to the yarn body, after running only a few kilometers of yarn, the first impression of the dense
area and the significant foreign fibers will appear.
The blue colored dense area is used to visualize the distribution and frequency of clearing limits for
the Foreign Matter (FD). By this means a quality analysis of the degree of contamination for different
yarns can be easily done.
With multicolored light sources the new FM sensor can see all colored foreign fibers and enables the
classification of vegetables separately. Having detected all the defects, the USTER QUANTUM 3
smartly splits the foreign matter into two pools, disturbing colored foreign fibers and mostly non disturbing vegetable foreign matter (see chapter 9). Separate limits for foreign fibers and vegetable matter can be defined.
Fig. 8-6, shows a dense area with yarn faults as seen by the USTER QUANTUM 3, with all the frequent remaining events recorded in the yarn (blue dots), and with the marked area of the yarn body
(blue area) and the area of the disturbing yarn faults (red dots).
The vertical scale represents the visual appearance or intensity and the horizontal axis represents the
FD faults length in cm.
Fig. 8-6
Display of the dense area and the scatter plot for foreign matter
USTER QUANTUM 3
8.3
Foreign fibers
Fig. 8-7
Display of the dense area and the scatter plot for foreign matter
Fig. 8-8
8.4
Display of the dense area and the scatter plot for foreign matter
USTER QUANTUM 3
Foreign fibers
8.3
Foreign fibers
8.3.1
There are various spinning mills which permanently eliminate foreign matter manually from the bales.
However, this method only allows the elimination of larger particles. Small foreign fibers such as human or animal hair cannot be eliminated with such methods because they cannot be detected.
The International Textile Manufacturers Federation ITMF investigates the contamination of cotton
bales on a global scale. The classification of foreign material in bales leads to Table 8-1. [5]
Type of contamination
Designation
Origin
Cotton-related contamination
honeydew
insects
leaf
cotton plant
stem
cotton plant
bark
cotton plant
trash
cotton plant
cotton boll
woven plastic
packing material
jute
packing material
plastic fragments
strings
bird feathers
natural contamination
grass
paper
leather
rust
oil / grease
rubber
stamp colorant
identification of bales
tar
Table 8-1
Depending on the growth area and the harvesting methods the type and number of foreign material
can change considerably.
USTER QUANTUM 3
8.5
Foreign fibers
Foreign fibers
Foreign fibers are all kinds of fiber type materials, which cling to the yarn. They can be of different
origin, composition, structure and color. They occur as single fibers as well as in fiber bundles. The
length of foreign fibers can vary considerably, but hardly exceeds a length of 7 cm.
Packing material
Cotton bales are often packed in polypropylene bags or other synthetic material after ginning. Other
kind of packing material made of natural fibers will not be discussed here.
Foreign fibers consisting of polypropylene are often white and therefore hardly detectable by electronic means. These fibers do not protrude and are not detected before dyeing or finishing. Thus, they
first become visible in the dyed woven or knitted fabric.
Fig. 8-9
Examples of packing material / Single fiber of a colored polypropylene string for packing the cotton fibers / Distance between black lines: 1 cm
Dirtiness
Dirtiness is caused of substances, which adhere to, are spun into or have penetrated into the yarn
body. The contamination of bales is usually attributed to transport damage, improper storage and print
color.
In the spinning mill, dirtiness as a foreign matter can be caused by
dust or very small particles from rubberized machine parts (e.g. press rollers) or drive belts, which
adhere to the yarn
In the yarn, dirtiness appears mostly as dark, brown or gray contaminants. In contrast to many foreign
fibers or packing materials, such faults are often very long, for example 5 cm or more. Due to the
length and the missing fibrous structure, these faults can usually be clearly identified.
8.6
USTER QUANTUM 3
Foreign fibers
Fig. 8-10
Vegetable matter
With vegetable matter, it is necessary to clearly differentiate between two categories
pieces of vegetables
Pieces of vegetables
Under this term, it is commonly understood some fragments of:
leaves
bark
stems
seed-coat fragments
The color is light to dark brown and the shape is irregular. The foreign matter adheres to or, in some
cases, is embedded in the yarn.
The frequency of such foreign matter depends on the degree of contamination of the fiber material
and on the efficiency of the blowroom equipment. In general, it can be said that the relative percentage of such foreign matter is usually very high.
Foreign matter in the form of vegetable fragments is normally brightened up almost completely in the bleaching process. But the effectiveness of the bleaching process depends on
the recipe and on the applied technology. Under normal conditions, this type of foreign matter is considered as non-disturbing after correct
bleaching. However, aggressive bleaching
agents are not allowed anymore.
Experience has shown that vegetables deriving
from weeds might remain as dark spots in the
yarn after bleaching. The monitoring of such
faults is recommended.
Fig. 8-11
USTER QUANTUM 3
8.7
Foreign fibers
The structure of the material is clearly fibrous. The color is usually light to dark-brown and the length
is in a short to medium range of approx. 1 to 2 cm. The fibers are extremely rigid and brittle, so that
they often protrude from the yarn and rarely cling tightly to the yarn body.
Due to the chemical similarity to the vegetable components of the fiber material, e.g. cotton, vegetable
packing materials are also affected by the bleaching process, whereby the recipe and the process
technology again play an important role.
Fig. 8-12
8.3.2
The investigation of ITMF every second year in the past has shown that the degree of contamination
of cotton bales depends very much on the growth area. Fig. 8-13 shows the growth areas with the
most contaminated bales.
8.8
USTER QUANTUM 3
Foreign fibers
Fig. 8-13
Growth areas with the highest foreign fiber contamination in cotton bales (Source: ITMF 2009)
Fig. 8-14 shows the growth areas with the least contaminated cotton bales.
Fig. 8-14
Growth areas with the lowest foreign fiber contamination in cotton bales (Source: ITMF 2009)
It has to be taken into consideration that those growth areas where cotton is harvested with machines
are less affected by inorganic matter because there is less contact between workers and cotton, but
the amount of vegetable can be higher.
USTER QUANTUM 3
8.9
Foreign fibers
It is evident that while a distinction between most contaminated and least contaminated cotton can
be made, there are no cotton varieties produced which have zero contamination. As can be seen
above, at least 5% of the produced bales from even the least contaminated origins have significant
levels of contamination.
8.3.3
If foreign material cannot be eliminated prior to the card the foreign material is cut into pieces by the
card. A piece of plastic can result in a number of individual foreign fibers after the card. As these fibers are mostly colored, the cluster of foreign fibers can easily be recognized in the card sliver.
These clusters of foreign fibers will lead to human interventions, consequently loss of production efficiency and labor costs, because the clearers on the winding machines will trigger foreign fiber alarm
due to the higher amount of foreign fibers within a short period.
Often in some spinning mills some of the foreign fibers are added accidentally through human ignorance, waste recycling etc. which contaminate the cotton fibers during the spinning process. For such
fibers the clearer as a monitoring system at the last stage of the spinning process is the only tool
which can eliminate such fibers.
Removed foreign
material in bale
Opening &
Cleaning
Line
Fig. 8-15
Card
sliver
Card
Yarn
Drawframe
Spinning
machine
The foreign fibers which cannot be eliminated during the spinning process will show up in the yarn
and have to be eliminated by the yarn clearer on the winding.
8.10
USTER QUANTUM 3
Foreign fibers
8.3.4
In order to understand the frequency of foreign fibers in spinning mills we have to consider that foreign fibers which exist as clusters in the card sliver are drawn several times in the spinning process
until they show up in the yarn. The more steps in the spinning process the more increases the distance from foreign fiber to foreign fiber in the yarn. Therefore, the distance between two foreign fibers
is longer in a ring spinning operation with combers than in an OE rotor operation.
Assumption: Plastic film prior to card of 2 cm2. Resulting cluster: 400 individual foreign fibers in the
card sliver (Fig. 8-15).
OE rotor spinning
Ring spinning
carded process
Ring spinning
combed process
Cards
Cards
Cards
Drawframes
OE rotor spinning
machines
Drawing
ratio
1200
to
10'000
Drawframes
Roving frames
Drawing
ratio
3000
to
30'000
Drawframes
Ribbon lap
machines
Ring spinning
machines
Combers
Winding
machines
Drawframes
Drawing
ratio
300'000
to
1'000'000
Roving frames
*0,2 to 1,5 m
*1 to 10 m
Ring spinning
machines
Winding
machines
*100 to 300 m
Fig. 8-16
In Fig. 8-16 the processing steps and the drawing ratios are shown for the 3 most important spinning
processes. It can be seen in the figure that the distance between two foreign fibers is short for short
spinning processes and long for spinning processes with many steps.
USTER QUANTUM 3
8.11
Foreign fibers
8.3.5
Fig. 8-17 shows the risk of a spinning mill which has the foreign fiber challenge not under control.
34800
36000
32000
28000
24000
18000
20000
16000
12000
7320
8000
3840
4000
600
1320
0
Bale
Fig. 8-17
Raw fabric
Finished fabric
(bleached)
Shirts
Retailer
The calculation is based on a bale of 480 lbs (217 kg). The price for the bale was USD 600. The spinners sales price for yarns made of this bale was USD 1320. The raw fabric was sold for USD 3840.
The finished fabric was sold for USD 7320.
The foreign fibers were only detected after bleaching. The finishing plant did not send the complaint to
the cotton trader, but to the spinner. Therefore, the finishing plant had a damage of USD 7320 per
bale which had to be paid by the spinner, but the spinner only earned USD 600 for the processing of
the entire bale.
Therefore, a reliable foreign fiber elimination system has to be installed in the spinning mill if the spinner wants to be the master of his destiny. Any claims to the spinner are much higher than the actual
cost of spinning since there is a significant value addition along the chain.
8.4
Uster Technologies has developed a classification matrix for foreign fibers and vegetable matters. Fig.
8-18 shows the structure of the classification matrix for foreign fibers, which represents the appearance (in %) and length (in cm). The appearance corresponds to the visibility of a fault.
8.12
USTER QUANTUM 3
Foreign fibers
Fig. 8-18
Classifying system for foreign fibers (Standard F classes (left) and extended F classes(right))
This matrix was developed in a similar way as Uster Technologies designed the matrix for thick places and thin places. A considerable amount of foreign fibers are located in the B1 class.
Therefore, the B1 class (B11 to B14) serves as a benchmark for recognizing the degree of contamination of the raw material. The experience values are the following:
Yarn type
Heavily contaminated
per 100 km
10
150
20
300
20
100
8.5
Table 8-2
Benchmarks for foreign
fibers
Clearing limits
The setting of the foreign fiber channels depends highly on the application profile of the yarn and the
amount of foreign fibers in the raw material.
Basically, it can be said: the longer a foreign fiber and the higher its color intensity:
As for regular yarn clearing, it is also valid for foreign fiber clearing:
More sensitive setting: more splices, but less remaining faults in the yarn
As for normal yarn clearing, it can also be said that foreign fiber clearing is a compromise between
quality and productivity.
USTER QUANTUM 3
8.13
Foreign fibers
8.5.1
Fig. 8-19 illustrates the relationship between the visual appearance and the length of foreign fibers.
The normal position for typical foreign fibers in a cotton yarn is shown. The limit between the diverse
foreign fibers cannot be drawn clearly and they also overlap partly.
Fig. 8-19
Vegetables:
- are mainly in short length ranges
- occur in the whole intensity spectrum from low to high
- should not be cleared, if possible, as they are possibly removed or neutralized in the following processes, particularly during the bleaching process
Foreign fibers:
- are mostly shorter than 7 cm, but thinner than vegetables
- must be cleared when exceeding the clearing limit
8.5.2
The FD-channel (Foreign matter Dark) is responsible for the clearing of dark foreign fibers in light
yarn. A dark foreign fiber has a low light reflection and, therefore, appears darker than the yarn.
8.14
USTER QUANTUM 3
Foreign fibers
8.5.3
Analogous to the optimization of the thick and thin places, the setting for the foreign fiber clearing
must also be started with the standard settings. According to the results, further adjustments have to
be carried out.
Fig. 8-20 describes this standard procedure when starting foreign fiber clearing with unknown cotton:
Fig. 8-20
USTER QUANTUM 3
8.15
Foreign fibers
Foreign fibers of different origin, composition, structure and color can be detected with foreign fiber
clearing. By selecting a limit only the disturbing foreign fibers are removed from the yarn. By using
FD, dark foreign fibers in light yarn are detected during production.
The setting of foreign material is mainly driven by the production lines in a mill; of course also in
blended or synthetic yarn the foreign material caused by fly or mix up can be eliminated.
Fig. 8-21 shows the clearing limit as shown in the setting window of the control unit. The USTER
QUANTUM 3 gives us the chance of determining our clearing limits by placing a maximum of 8 set
points FD1 to FD8. In Fig. 8-21, we can see 3 setting points (red rectangle) and the clearing limit for
FD foreign fibers. By this setting method the effects of a change of the parameters on the clearing
limit can be demonstrated directly.
As soon as we enter new values at set point, the next one will appear until we reach the 8th set point.
This means after we entered the values for FD1, set point FD2 will appear and it will continue the
same way.
Fig. 8-21
Set points have two parameters. These are: sensitivity (%) and reference length (cm).
Intensity
The sensitivity (%) is a parameter for the clearing limits of the corresponding fault channel. The sensitivity setting shifts the clearing limit upwards (less sensitive) or downwards (more sensitive). (FD1=
40%, Fig. 8-21).
Reference length
The reference length (cm) is a parameter for the clearing limits of the corresponding fault channel and
shifts the clearing limit to the right (less sensitive) or to the left (more sensitive) (FD1 = 0.6 cm,
Fig. 8-21).
8.16
USTER QUANTUM 3
Foreign fibers
8.5.4
As we mentioned in the previous chapter, the dense area is the display of the range where foreign
fibers are occurring very frequently. This display of the dense area helps the user to set a clearing
limit easier with an optimal balance between quality and productivity (Fig. 8-22).
Similar to the yarn body, after running only a few kilometers of yarn, the first impression of the dense
area and the events will appear. In order to see the dense area, the user should press the dense area
key (Fig. 8-23). Besides the dense area, also the scatter plot of the cut faults and remaining events,
and the number of expected fault cuts per 100 km together with the used setting limits will appear
directly on the same setting page (Fig. 8-24).
Pressing
key presents
The dense area.
Scatter plot of the cut faults
and remaining events.
Number of expected fault cuts
/ 100 km.
Clearing limit
Red dots = cut yarn faults.
Blue dots are remaining events
Dense area
= Proposes the starting point
for the clearing limits based on the
dense area.
Fig. 8-22
With the USTER QUANTUM 3, we have a very useful and smart tool to find the right starting point
for the new clearing limits. The Smart Limit function proposes a starting point for the clearing limits
based on the yarn body and also provides a cut forecast to facilitate faster setup of clearing limits.
The setting of USTER QUANTUM 3 can be done simply in one step (Fig. 8-23, Fig. 8-24):
Fig. 8-23
USTER QUANTUM 3
Fig. 8-24
8.17
Foreign fibers
After pressing the smart limit key, a small window with the two appropriate keys to adapt and optimize
the smart limit for foreign fibers appears (Fig. 8-25). The Smart Limit has been developed to propose
a starting point for the clearing limits by pressing one button. This proposal can be altered by up and
down keys to optimize the settings according to the individual quality requirements and productivity.
Every change of setting will automatically initiate a new calculation of the cut forecast. It is recommended to use the Smart Limit function after a minimum of 30 km of yarn has already been wound.
This length includes all the clearers of the machine.
Fig. 8-25
Besides the smart limit function, of course the foreign fiber (FD) and vegetable matter clearing (VEG)
classification is still a very powerful tool where we can refer our last decision (Fig. 8-26).
Cuts/100km
Total yarn events
/100km
Fig. 8-26
8.18
FD online classification
USTER QUANTUM 3
Foreign fibers
The red figure in each class indicates how many foreign fibers were eliminated by the clearer within
this class and the black figure represents the number of foreign fibers which were detected in the
class.
8.6
USTER QUANTUM 3
8.19
Foreign fibers
Fig. 8-27
Fig. 8-28 shows a practical example for a classification matrix of a carded cotton yarn.
Fig. 8-28
8.20
USTER QUANTUM 3
Foreign fibers
8.6.1
Domain of
yarn clearers
Domain of manual removal
Domain of automatic removal
systems prior to card
Fig. 8-29
0,001
0,01
(diameter 10m)
(diameter 100m)
0,1
1,0
10 cm2
Size of foreign
material
It is evident that the type and frequency of foreign matter require an effective system to combat this
problem. Over the years spinning mills used the following methods to eliminate disturbing foreign matter in order to keep the defects within acceptable limits:
In some cases, especially in vertically integrated textile mills, the mending of defects after finishing the
fabric is also common practice, but only part of the foreign fibers can be extracted from the fabric.
Cotton selection
It makes sense in a spinning mill to know the growth areas with low foreign material contamination. It
must be the aim to order cotton from areas with a low number of foreign material content to keep the
risk of remaining foreign fibers low and to improve the efficiency of the removal systems both human
and electronic. Further, they help to keep the number of foreign fiber cuts with the clearer on a low
level.
This is especially valid for end customers who ask for zero foreign fibers as a mandatory requirement, and where a significant premium is paid for such a high value addition. If the premium which the
spinner can realize is not significant, choosing low contamination cotton can often lead to other issues
seriously affecting profit margins.
USTER QUANTUM 3
8.21
Foreign fibers
This may be cotton with higher nep content, higher short fiber content and higher cotton prices. Further, cotton supply contracts in general do not include contamination level as a dispute clause, with
the result that losses cannot be recovered in case contamination expectations are not met.
Manual labor
In developing countries, low labor costs allow use of manual inspection of cotton to remove the major
defects. Typically mills use manual labor to open bales, inspect for contamination and repack them
again. The number of people or the work load employed varies from mill to mill and the end use. Estimates from spinning mills in China show between 1 person per 1 to 3 bales per day depending on
the quality demand. Therefore, in an average size spinning mill with 30000 spindles the number of
employees who do these jobs vary from 60 to 180 people.
Fig. 8-30
8.22
USTER QUANTUM 3
Foreign fibers
Since the clearers are integrated in the automatic winder, they are in a position to make the final inspection and monitor every millimeter of yarn. Further, the clearers are today capable of detecting the
finest defects not clearly visible to the naked eye. However, many of these very fine fibers may be
visible after subsequent processes such as bleaching, dyeing, etc. This includes white and transparent polypropylene defects. The clearer can replace each disturbing defect with a splice, thereby eliminating the defect from the final package to the weaver or knitter.
Fig. 8-29 is, therefore, a very important figure to understand the mechanism of foreign material. This
figure also shows that the foreign material removal systems prior to the card have little influence on
the cut rate of the clearers, because most of the foreign fibers which are eliminated by the clearers
cannot be recognized by systems prior to the card.
It also has to be taken into consideration that the automatic foreign material elimination systems prior
to the card eject a considerable amount of cotton together with the foreign materials which must be
separated manually from the real foreign materials to keep the waste on a reasonable level.
Fig. 8-31
Calculation method
Result
1200/24 hours
Efficiency 80%
Ejections prior to card
Number of foreign fiber cuts on the winding machine
Winding speed: 1400 m/min
Foreign fiber cuts per winding position and per day
Number of foreign fiber cuts with 600 winding positions
Table 8-3
2 opening/cleaning lines
1/100 km
25 per 100 km
of yarn
71,43 min
25 1440 / 71,43
504 cuts
600 504
302400 cuts
USTER QUANTUM 3
8.23
Foreign fibers
1920
302400
This calculation clearly indicates that the number of foreign fiber cuts by the clearer is more than 100
times higher than the number of ejections by the foreign fiber removal system prior to the card.
This also explains that the number of small foreign items is much higher than the number of large
particles which can be eliminated prior to the card. If the foreign material removal system prior to the
card is switched off, it does hardly affect the number of clearer cuts for the same reason. However,
the foreign matter removal systems prior to the card can avoid that large foreign particles are cut in
hundreds of fibers which later requires a human intervention to eliminate the foreign fiber clusters in
the card sliver or to replace the affected roving in case of a foreign fiber alarm of the clearer.
8.6.2
If the foreign material removal system prior to the card is not in a position to eliminate larger foreign
particles because the particles are embedded in a tuft, the card will produce a large number of individual foreign fibers which form a cluster in the card sliver as mentioned above. After various drawing
processes they will end in the yarn. The frequency depends on the number of drawing processes as
mentioned above in Fig. 8-16.
8.6.3
Ring spinning
Recognition with foreign fiber alarm. If the number of foreign fiber counts oversteps a preset threshold
the winding machine triggers the red light at the critical winding position which also needs a human
intervention or the winder automatically ejects the contaminated bobbin.
8.24
USTER QUANTUM 3
Foreign fibers
8.6.4
28,5
4,0
30,0
Foreign fibers
30,0
92,5
0,9 min
Table 8-4
Limits of foreign fiber
elimination on winders
With 0,9 minutes between two splices we are approaching the limit of admissible stops on the winding
machine. It is not recommended to process heavily contaminated cotton and expect afterwards that
the clearer can produce a yarn which is completely free of foreign fibers.
8.6.5
Process disturbances while beaming, weaving and knitting caused by foreign matter
Table 8-5 shows the influence of remaining foreign fibers in yarns on subsequent processing stages
in the textile chain.
Process
Beaming
up to 50%
Weaving
up to 50%
Knitting
1 to 2 per hour
up to 40%
8.6.6
Table 8-5
Experience values / end
breaks in beaming, weaving, knitting caused by
foreign matter
Based on the discussions in this paper, the following approach is recommended for elimination of
foreign fibers:
Foreign fiber clearers are mandatory to eliminate foreign fibers, to fulfill the end user quality
needs and to assess the overall cotton quality (using classification figures)
USTER QUANTUM 3
8.25
Foreign fibers
Installing automatic detection systems prior to the card helps in reducing manpower, eliminating
major defects to reduce stoppages, to reduce human intervention and to maintain consistency in
FF clearing
Random manual inspection of cotton batches helps to identify and track the type and amount of
defects in order to optimize purchase decisions
Importing cleaner cotton helps to fulfill demands for a cotton yarn with small amount of foreign
fibers
To prove the above approach Uster Technologies conducted a trial in a Chinese Spinning Mill. The
following is the description and results of the field trials.
8.6.7
Test procedure
A field test was carried out in a quality oriented Chinese spinning mill, where the following foreign
matter removal systems were available:
Four tests were carried out to check the efficiency of the three above mentioned elimination systems.
The final packages were sent for weaving (as weft) and knitting (circular knitting machine). The tests
were carried out in a mill where the yarn was woven and knitted. Afterwards, textile experts checked
each of the trial fabrics and counted the remaining foreign fibers in the fabrics.
All defects that were disturbing were counted. This means that very short defects were included as
well, though they were beyond the clearing limits. Dirt was not considered since it disappears in subsequent processes.
The yarn produced was a Ne 32/1 (18,7tex), produced from mainly Xinjian province, but also included
some imported cotton from Benin, Zimbabwe and Uzbekistan. The daily production of this mill is
about 22 tons of ring spun yarn.
8.26
USTER QUANTUM 3
Foreign fibers
Knitted fabrics
This mill sells knitted fabrics as first grade if the number of foreign fibers in a knitted fabric of 20 kg
weight is less than 10. The weight of 20 kg is equivalent to a length of the knitted fabric of 120 m.
A first test was made without any foreign material elimination systems. The fabric was knitted on a 30
circular knitting machine, 96 feeders, fabric weight 125g/ 75cm. The fabric inspection experts could
find 49 foreign fibers in the grey knitted fabric of 20 kg (Fig. 8-33).
Fig. 8-32
A second test was carried out with a visual check of the raw material and simultaneously with an electronic elimination system prior to the card. With these two elimination methods, the amount of foreign
fibers which the experts counted in the knitted fabric dropped from 49 (without any elimination system) to 38 (Fig. 8-33).
Number of
foreign fibers
50
49
40
38
30
20
Tolerated limit:
10 foreign fibers
10
0
Without removal
systems
Fig. 8-33
Test result with knitted fabrics, Litai Ne 32, 1 grade < 10 defects / 20 kg of knitted fabric
A third test was made by using the USTER QUANTUM clearer only. The number of foreign fiber cuts
of the clearer was 30 to 35 per 100 km. The visual check of the grey knitted fabric has resulted in 8
foreign fibers remaining (Fig. 8-34).
USTER QUANTUM 3
8.27
Foreign fibers
Number of
foreign fibers
50
49
40
30
20
Tolerated limit:
10 foreign fibers
10
8
0
Without removal
systems
Fig. 8-34
With yarn
clearer only
A fourth test was undertaken with all the elimination systems. After knitting of a roll with 20 kg, the
experts counted 6 remaining foreign fibers (Fig. 8-35).
Number of
foreign fibers
50
49
40
30
20
Tolerated limit:
10 foreign fibers
10
6
0
Without removal
systems
Fig. 8-35
Conclusion
It was only possible to reduce the amount of foreign fibers below the given threshold of 10 per 20 kg
of knitting with the USTER QUANTUM clearer because the clearer is the only tool which can also
detect and eliminate small foreign fibers.
If this figure has to be improved, the number of foreign fiber cuts of the clearer per 100 km has to be
increased.
8.28
USTER QUANTUM 3
Foreign fibers
Woven fabrics
This mill also sells woven fabrics as first grade if the number of visually counted foreign fibers in a
woven fabric of 100 square yards is below 28.
A first test was made without any foreign material elimination systems (Fig. 8-36). The experts could
find 56 foreign fibers in the grey woven fabric of 100 square yards.
A second test was carried out with a visual check and simultaneously with an electronic elimination
system prior to the card. With these two elimination methods the amount of foreign fibers which the
experts counted in the woven fabric dropped from 56 (without any elimination system) to 52 (Fig.
8-36).
Fig. 8-36
st
Test results with woven fabrics, Litai Ne 32, 1 grade < 28 defects / 100 square yards
A third test was made by using the USTER QUANTUM only. The number of foreign fiber cuts of the
clearer was 30 to 35 per 100 km. The visual check of the grey woven fabric has resulted in 26 foreign
fibers (Fig. 8-37).
Number of
foreign fibers
60
50
56
40
30
26
20
Tolerated limit:
28 foreign fibers
10
0
Without removal
systems
Fig. 8-37
With yarn
clearer only
USTER QUANTUM 3
8.29
Foreign fibers
A fourth test was undertaken with all the elimination systems. The experts counted 16 remaining foreign fibers per 100 square yards (Fig. 8-38).
Number of
foreign fibers
60
50
56
40
30
Tolerated limit:
28 foreign fibers
20
16
10
0
Without removal
systems
Fig. 8-38
Conclusion
It was only possible to reduce the amount of foreign fibers below the threshold of 28 per 100 square
yards with the USTER QUANTUM clearer because the clearer is the only tool which can also detect
and eliminate small foreign fibers.
If this figure has to be improved, the number of foreign fiber cuts of the clearer per 100 km has to be
increased.
8.7
Depending on the application of the yarn, a foreign fiber can have different effects on the woven or
knitted fabric. In knitting, the loop formation causes a shortening of the yarn, including the foreign fiber, which leads to a concentration of the color contrast. This means, that short foreign fibers have a
more disturbing effect than in a knitted fabric. Short foreign fibers protrude from the woven fabric, unless it exhibits a high density and stiffness. Only a combination of the intensity and the length of a
foreign fiber have a disturbing effect on the eye.
In the following figures (Fig. 8-39 and Fig. 8-40) examples for foreign fiber in a woven and in a knitted
fabric are shown.
8.30
USTER QUANTUM 3
Foreign fibers
Fig. 8-39
Fig. 8-40
USTER QUANTUM 3
8.31
Foreign fibers
In general, 4 5 disturbing foreign fibers are accepted in a piece of knitted fabric (about 80 120 m)
today. As disturbing are regarded:
Fig. 8-41 to Fig. 8-46 show foreign fibers in various garments. The zoomed pictures show different
colored foreign fibers. In Fig. 8-41 and Fig. 8-42, a blue colored foreign fiber can be observed. The
garment was produced with 100% cotton and, after the bleaching process, it had a uniform white color. But the blue colored foreign fiber disturbs the knitted fabric appearance.
Fig. 8-41
Fig. 8-42
In Fig. 8-43 and Fig. 8-44, a red colored foreign fiber can be observed. The garment is produced with
100% cotton, and, after bleaching process, it had a white color. But the red colored foreign fiber disturbs the knitted fabric appearance.
Fig. 8-43
8.32
Fig. 8-44
USTER QUANTUM 3
Foreign fibers
Fig. 8-45 and Fig. 8-46 show a blue colored foreign fiber in mens cardigan. The product was produced with 100% combed cotton.
Fig. 8-45
8.7.1
Fig. 8-46
In Table 8-6 and Table 8-7, the origin of the faults related to yarn contaminations is given. Possible
reasons and preventive measures to avoid such faults are explained and various USTER tools for
improvement are presented.
CONTAMINATION
Origin of Faults
Bale management
Prefer when possible to use cotton with low content of foreign fibers.
Sometimes spinning mills tend to create or intensify the contamination
problem. A popular mistake is the use of plastic bags for the waste collection and transportation inside the spinning mill.
Blowroom
Cards
Drawing frame
Combing
Table 8-6
USTER QUANTUM 3
8.33
Foreign fibers
Improvement
Quality control of foreign fibers with USTER TESTER when dealing with
new raw material
Separate outlier bobbins with too many foreign fibers with quality alarm
settings
8.34
USTER QUANTUM 3
9.1
Introduction
Uster Technologies has now many years of foreign fiber experience with USTER QUANTUM. This
experience helped us to recognize opportunities to improve the features of the USTER QUANTUM
3.
Some of the customers are also interested to eliminate vegetables, but many customers are eager to
only remove real foreign fibers because they can prove that the vegetables are not visible anymore
after bleaching.
The elimination of inorganic foreign fibers only and keeping as much vegetables in the yarn as possible can be applied for the following purposes:
Reduction of cuts while keeping the eliminated number of disturbing foreign fibers constant
Keeping the number of cuts constant but eliminating more and finer foreign fibers with the same
machineefficiency.
Uster Technologies has developed a tool for the USTER QUANTUM 3 to separate foreign fibers and
vegetables. This feature is named Vegetable Clearing. The new foreign matter (FM) sensor of the
USTER QUANTUM 3 has multicolored light sources and can detect various colored foreign fibers
and also enables the classification of vegetables separately. The USTER QUANTUM 3 smartly splits
the foreign matter into two populations, disturbing colored inorganic foreign fibers and non disturbing
vegetable foreign matter. Separate limits for foreign fibers and vegetable matter can be defined.
Fig. 9-1
Various vegetable matters in yarns at different magnification. The distance between the black lines
is 10 mm
USTER QUANTUM 3
9.1
9.1.1
Vegetable matter
pieces of vegetables
Pieces of vegetables
Under this term, it is commonly understood:
leaf fragments
bark fragments
stem fragments
seed-coat fragments
The color is light to dark brown and the shape is irregular. The foreign matter adheres to or, in some
cases, is embedded in the yarn.
The frequency of such foreign matter depends on the degree of contamination of the fiber material
and on the efficiency of the blow-room equipment. In general, it can be said that the relative percentage of such foreign matter is usually high.
Foreign matter in the form of vegetables is normally brightened up almost completely in the bleaching
process. But the effectiveness of the bleaching process depends on the recipe and on the applied
technology. Under normal conditions, this type of foreign matter is considered as non-disturbing.
Experience has shown that vegetables deriving from some weeds might remain as dark spots in the
yarn after bleaching. The monitoring of such faults is aspired.
Fig. 9-2
Examples for seed-coat fragments (left) and short vegetables (right) in yarns
9.2
USTER QUANTUM 3
The structure of the material is clearly fibrous. The color is usually light to dark-brown and the length
is in a short to medium range of approx. 1 to 2 cm. The fibers are extremely rigid and brittle, so that
they often protrude from the yarn and rarely cling tightly to the yarn body (Fig. 9-3).
Due to the chemical similarity to the vegetable components of the fiber material, e.g. cotton, vegetable
packing materials are also affected by the bleaching process, whereby the recipe and the process
technology again play an important role. Usually, this type of foreign matter can only be partly brightened through bleaching.
Fig. 9-3
9.1.2
In order to differentiate between vegetables and foreign fibers, different possibilities were tested. The
chosen approach was:
A coarse foreign fiber or a bundle of foreign fibers has a high reflection and a considerable mass
The vegetable matter clearing was developed only for the capacitive clearer.
9.2
The Dense Area, an innovative and unique feature of the USTER QUANTUM 3 has already been
explained for foreign matter in Chapter 8. The USTER QUANTUM 3 has a similar dense area for
vegetable matter clearing. The dense area for vegetable matter is also the display of the range where
vegetable matters are occurring very frequently. The brown colored dense area is used to visualize
the distribution and frequency of clearing limits for the vegetable matter.
USTER QUANTUM 3
9.3
The dense area depends on the raw material. If a yarn produced from cotton having a lot of foreign
matter and vegetables, then the dense area will be wider, and a high number of cuts have to be expected.
Similar to the yarn body, after running only a few kilometers of yarn, the first impression of the dense
area and the significant foreign fibers will appear.
Fig. 9-4 shows a dense area for inorganic foreign matter with vegetable clearing and Fig. 9-5 shows a
dense area for vegetable matter with larger vegetables shown as single dots as seen by the USTER
QUANTUM 3, with all the frequent events recorded in the yarn (brown dots), and with the dense area
of insignificant events (brown area).
The vertical scale represents the visual appearance or intensity and the horizontal axis represents the
vegetable faults length in cm.
Fig. 9-4
Display of the dense area and the scatter plot for organic matter only
As shown in Fig. 9-6, two separate limits for inorganic fibers and vegetable matter are shown on the
vegetable clearing page. The brown dots between the FD and vegetable clearing curves represent in
cuts savings.
Fig. 9-6
9.4
USTER QUANTUM 3
Fig. 9-7 shows how the foreign matter can be separated into inorganic foreign fibers and vegetable
matter.
Matrix of foreign matter showing clearing curve for inorganic matter (VEG Clearing)
Fig. 9-7
USTER QUANTUM 3
9.5
9.3
Uster Technologies has developed a classification matrix for foreign fibers and vegetable matters. Fig.
9-8 shows the structure of the classification matrix for foreign fibers, which represents the appearance
(in %) and length (in cm).
Fig. 9-8
9.4
Classifying system for vegetables (Standard vegetable classes (left) and extended vegetable classes (right))
Clearing limits
As a result of intensive field tests, the vegetable clearing was defined. Vegetables are part of foreign
matter. However with most common bleaching processes, vegetables become invisible after bleaching. Therefore mostly it is not necessary to remove them. Since the proportion of vegetables is rather
high in cottons of some growth areas this results in a substantial drop in production if all the larger
vegetables have to be removed and at the same time limits the ability to remove inorganic disturbing
fibers.
The USTER QUANTUM 3 separates vegetables from other foreign matter. This offers better selectivity in foreign matter clearing and save cuts significantly. The reduction of cuts is reached by allowing vegetables which will not disturb the downstream process to pass (they will not be cut). The feature is used for articles that will undergo a bleaching process.
In most situations vegetables are not disturbing. However long and thick vegetables have to be removed since they can cause breaks in downstream processes. The Vegetable Clearing is a very useful tool to distinguish between organic and inorganic fibers. Since vegetables are not visible after the
bleaching process, they can often remain in the yarn. The result is a reduction of foreign fiber cuts.
There might be a need to cut long or intense vegetables to avoid warping or knitting breaks in subsequent processes.
9.6
USTER QUANTUM 3
Fig. 9-9
Cut savings with vegetable clearing. The colored area between the two clearing curves shows the
cut savings when applying Vegetable Clearing (right).
In applications where the bleaching agents are milder, vegetables do not completely disappear for the
human eye after bleaching and need to be treated like colored foreign fibers. Therefore they have to
be removed according to the quality needs.
9.4.1
The built-in intelligence of USTER QUANTUM 3 divides the vegetables into more or less disturbing
events according to the end product requirements. This is expressed by the way of choosing close,
medium and open setting.
The USTER QUANTUM 3 has a vegetable Clearing feature displaying a dense area and four different setting possibilities. These are named FD switched off, close, medium and open. The USTER
QUANTUM 3 also provides vegetable classification. Three clearing limit possibilities (close, medium,
open) are always synchronized to the FD clearing limit. The difference between the FD and vegetable
clearing results in cut savings.
As FD: The vegetable clearing is switched off. (All the vegetables are classified as foreign matter
and they are removed by using FD clearing limit.)
Close: Only small vegetables remain in the yarn. Of course this will only result in a small saving
of FD cuts.
Medium: Small to medium vegetables remain in the yarn. This will reduce the number of FD cuts
to a large extend.
Open: Most of the vegetables remain in the yarn and the highest savings of cuts will be reached.
The Vegetable Clearing is only available when using the capacitive clearer.
The USTER QUANTUM 3 provides Vegetable Clearing with a dense area and three setting possibilities.
USTER QUANTUM 3
9.7
Fig. 9-10
FD setting only
Fig. 9-14
Vegetable settings close
Fig. 9-11
Vegetable settings
close
Fig. 9-12
Vegetable settings
medium
Fig. 9-15
Vegetable settings medium
Fig. 9-13
Vegetable settings
open
Fig. 9-16
Vegetable settings open
For each group or winding position the VEG events are displayed as individual dots on the classification matrix.
Fig. 9-17
9.8
Display of the dense area and Vegetable Clearing curve. In the top right corner of the matrix the FD
cuts saved are displayed.
USTER QUANTUM 3
Recommendations:
Generally, we are recommending using medium level, if the used raw material (cotton) contains
vegetables. If the user is sure that the used raw material does not contain any vegetables, then the
vegetable clearing feature should not be used. For other raw material types like synthetics or worsted
yarns the use of this function is not recommended.
Besides the clearing limit function, of course the foreign fiber (FD) and vegetable matter clearing
(VEG) classification is a very powerful tool to minimize the number of cuts.
Fig. 9-18
Display of the limits for Vegetable Clearing. This Vegetable Clearing allows the saving of 15,2 cuts
per 100 km.
9.5
9.5.1
Field test
In this field test, an investigation about the contamination and its impact on yarns has been done. In
order to realize the effect of the contamination on the final product, the after treatment processes of
the yarn were simulated.
For this field test, 100% medium staple Greek cotton was used. The contamination from the blowroom over a lot of seasons was collected and classified into categories according to their frequency
and appearance characteristics. Then the contaminated samples together with cotton yarn were prebleached and bleached.
The material after the treatment was analyzed under a microscope and pictures were taken.
USTER QUANTUM 3
9.9
The results of the survey had shown that more than 70% of the foreign material that had been found
in the blow-room was decolorized with pre-bleaching including feathers, cotton plant residuals, colored cotton due to infection. The plastics or wool was not affected by bleaching. The vegetable residuals were not fully always decolorized but some of them remain of a yellowish shade after prebleaching. The majority of the colored contaminants were from the strings which have been used for
cotton transportation and ginning and from fabrics (cloths).The non-affected material was inorganic
material (Fig. 9-19 and Fig. 9-20).
Fig. 9-19
Effect of bleaching on foreign fibers. The inorganic foreign fibers hardly change the color.
Fig. 9-20
Effect of pre-bleaching on vegetable matter. Already after pre-bleaching most the vegetable fibers
do not differ in color from normal cotton.
9.10
USTER QUANTUM 3
9.5.2
In Table 9-1 and Table 9-2, the origin of the faults related to yarn contaminations is given. Possible
reasons and preventive measures to avoid such faults are explained and various USTER tools for
improvement are presented.
VEGETABLE MATTER CONTAMINATION
Origin of Faults
Bale management
Optimize and control the settings and maintenance of the blowroom machines
Cards
Drawing frame
Combing
Table 9-1
Improvement
Separate outlier bobbins with too many foreign fibers with quality alarm
settings
Preventive measures and tools for the management of foreign fibers and vegetable matter
USTER QUANTUM 3
9.11
9.12
USTER QUANTUM 3
10
10.1
Introduction
10
With the foreign fiber measuring method, only colored foreign fibers can be detected in a yarn. Foreign fibers consisting of polypropylene, however, are often white or without any color and are therefore, hardly detectable with the foreign fiber detection principle because there is no color difference to
cotton. Therefore, a new measuring principle was developed to find these foreign fibers.
Polypropylene fibers are mostly stiff, ribbon-like fibers which often protrude from the yarn body (refer
to Fig. 10-1). Polypropylene is used as a package material for cotton bales and as such the source of
the contamination of cotton.
Fig. 10-1
As they are not found with the conventional foreign fiber detection, they are only detected after dyeing
or finishing. Thus they first become visible in the finished woven or knitted fabric. A polypropylene
fiber is shown in a raw fabric (Fig. 10-3) and after dyeing (Fig. 10-4).
There are more and more complaints in the textile chain because of polypropylene fibers remaining in
the fabric. The damages are enormous since many polypropylene fibers can only be detected in finishing.
USTER QUANTUM 3
10.1
10
Fig. 10-2
Fig. 10-3
10.2
USTER QUANTUM 3
Fig. 10-4
10
The fact that the PP fibers do not absorb dyestuff used for cotton will always lead to visible PP fibers
in fabrics.
The aim of the USTER polypropylene fiber detection development was not only to detect these white
or translucent fibers, but also to be able to classify the length and the thickness reliably.
A considerable part of cotton bales are embedded in polypropylene bags. If these bags are not handled carefully either after the ginning process, on transit or in the blow room of spinning mills, there is
a high probability that polypropylene fibers contaminate the cotton.
The USTER QUANTUM 3 has a new, smart polypropylene (PP) clearing system. The clearer settings are very easy since the system proposes a smart limit which is a good starting point again at the
touch of a button. This new smart clearing limit is different from the previous detection system. Further, the new USTER QUANTUM 3 polypropylene clearing has no count, length or speed restrictions. The system is also less affected by environmental conditions. The PP option is available for
all capacitive clearers (C15 and C20). With the help of the USTER QUANTUM 3 smart polypropylene clearing, the user can detect very fine and short polypropylene fibers.
Fig. 10-5
USTER QUANTUM 3
10.3
10
Splices / 100 km
34
30
30
Polypropylene fibers
Total splices
96
Table 10-1
Number of splices
per 100 km, count Nec 30,
100% cotton, combed
Fig. 10-6 below shows the frequency of PP fibers taking into account the process (carded or combed)
and the count of the yarn. It can be seen that the number of PP fibers decreases when a combing
process is added and the yarn count becomes finer. In combing the stiff large PP fibers can be removed. The finer the count, the more short fibers are removed thus more PP fibers can be eliminated as well. On the ring spinning machine, PP fibers often lead to yarn breaks on medium and fine
yarn counts since the PP fiber weakens the yarn. Furthermore, finer yarn counts have a smaller number of fibers in the cross-section and, therefore, a PP fiber has a higher effect on the end break rate
than on a coarse yarn. In a field trial carried out the number of detected PP fibers in carded yarns was
by 38% higher compared to combed yarns (see Fig. 10-7 and Fig. 10-8).
A PP fabric moving through the card shows up as a cluster of fine fibers in the card sliver. For a fine
yarn the drawing ratio is much higher than for a coarse yarn. Therefore, the distance from PP fiber to
PP fiber is higher and, therefore, the number of PP fibers in fine yarn is lower per unit length.
Fig. 10-6
10.4
Frequency of PP fibers in carded and combed cotton ring yarn (RSM = ring spinning machine)
USTER QUANTUM 3
10
To illustrate Fig. 10-6 above, the following trials were carried out in a 100% cotton spinning mill. PP
fibers were extracted from a carded yarn, Nec 14, and from a combed yarn, Nec 20. For both materials the winding machine was running at the same speed of 1300 m/min. The same PP settings were
used.
In Fig. 10-7 one can see some of the big and stiff polypropylene fibers, which were removed on the
winding machine from a carded yarn, Nec 14. Altogether 3.4 PP fibers were detected per 100 km.
Fig. 10-7
In Fig. 10-8 the polypropylene fibers, which were extracted from a combed yarn, Nec 20 can be seen.
The PP clearer detected 2.1 PP fibers per 100 km.
Fig. 10-8
USTER QUANTUM 3
10.5
10
It can also be observed that the PP fibers from the combed yarn are much finer than the PP fibers
taken out of the carded yarn. This is due to the additional combing process which eliminates many
coarse PP fibers. In Fig. 10-9, one can see PP fibers taken out of a compact yarn Nec 30. They are
even finer than the ones shown in Fig. 10-7 and Fig. 10-8.
Fig. 10-9
Fig. 10-10
10.6
USTER QUANTUM 3
10
In Fig. 10-11, the yarn count frequency of ring-spun yarns produced worldwide is shown. It can be
noticed that the entire count range is covered with PP clearing.
Fig. 10-11
10.2
Scatter plot
The USTER QUANTUM 3 interprets and displays the polypropylene characteristics with the help of a
scatter plot. It is the graphic representation of the detected PP events within a classification matrix.
Each event is marked with one dot. The vertical scale represents the visual appearance or intensity
and the horizontal axis represents the vegetable fault length in cm. Fig. 10-12 shows a scatter plot
with yarn faults as seen by the USTER QUANTUM 3, with all the frequent events recorded (grey
dots), the actual clearing limit and the area of the disturbing yarn faults (red dots).
Fig. 10-12
The scatter plot also depends on the raw material. If a yarn is produced from cotton having a lot of
polypropylene fibers the scatter plot will be denser with many dots, and a high number of cuts has to
be expected.
USTER QUANTUM 3
10.7
10
Fig. 10-13
Yarn Ne 40, 100% cotton, combed, knitting, 1438 km. Low amount of PP fibers:
1,7 PP fibers per 100 km
Fig. 10-14
Fig. 10-15
Yarn Ne 40, 100% cotton, combed, compact, 2298 km. Low amount of PP fibers:
3,2 PP fibers per 100 km
Fig. 10-16
10.8
USTER QUANTUM 3
10.3
10
10.3.1 Standard way of optimizing clearing limits: Manual clearing limits entry
Fig. 10-17 shows the clearing limit as shown in the setting window of the Central Clearing Unit (CCU).
The USTER QUANTUM 3 gives us the chance of determining our clearing limits by placing a maximum of 8 set points PP1 to PP8. In Fig. 10-17, we can see 4 setting points (red rectangle) and the
clearing limit for PP polypropylene. By this setting method the effects on the change of the parameters on the clearing limit can be demonstrated directly.
As soon as we enter new values at set point, the next one will appear until we reach the 8th set point.
This means after we enter the values for PP1, set point PP2 will appear and it will continue the same
way.
Fig. 10-17
Set points have two parameters. These are: intensity (%) and reference length (cm).
Intensity
The intensity (%) is a parameter for the clearing limits of the corresponding fault channel. The intensity setting shifts the clearing limit upwards (less sensitive) or downwards (more sensitive). PP1 = 30%,
Fig. 10-17.
Reference length
The reference length (cm) is a parameter for the clearing limits of the corresponding fault channel and
shifts the clearing limit to the right (less sensitive) or to the left (more sensitive). PP1 = 0.4 cm,
Fig. 10-17.
USTER QUANTUM 3
10.9
10
Pressing
key presents
Scatter plot of the cut faults and remaining events.
Number of expected fault cuts / 100 km.
Clearing limit
Red dots = cut yarn faults.
Grey dots = remaining events.
= Proposes the starting point for
the clearing limits based on the body.
Fig. 10-18
As soon as the button at the smart limit window is pressed, the yarn body and the expected cut figure
per 100 km is displayed on the same setting page (Fig. 10-18).
The sensitivity of the smart limit can be changed stepwise by pressing up and down keys, whereupon
the limit moves away from or approaches the area of frequent events. At the same time, the new calculated setting point values appear in blue color. Every time this key is pressed, the limit moves further away or approaches the scatter plot, and the adapted setting limits are presented in blue color.
Simultaneously, the expected cut figure is calculated based on the real yarn events.
10.10
USTER QUANTUM 3
10
Fig. 10-19
PP yarn faults are displayed together with all the other yarn faults of the machine, a group or a winding position. It can be switched from absolute values to values per 100 km.
Fig. 10-20
USTER QUANTUM 3
10.11
10
10.4
Polypropylene fibers can hardly be recognized in grey fabrics, because they cannot be distinguished
from the point of view of color. However, they can easily be recognized after dyeing because polypropylene fibers do not absorb textile dyestuff.
Polypropylene fibers cannot be recognized with sensors which need a difference in colour for a distinction. Therefore, a particular sensor technology is used to eliminate polypropylene fibers.
Fig. 10-21 and Fig. 10-22 show a white polypropylene fiber knitted into a turtleneck sweater. A considerable proportion of cotton bales are packed in white polypropylene bags. If these bags are not
handled carefully, either after the ginning process, during transportation or in the blowroom of the
spinning mill, there is a high probability that polypropylene fibers will contaminate the cotton. Such
fibers are spun into yarns.
White polypropylene fibers can hardly be recognized in grey fabrics, because they cannot be distinguished from the point of view of color. However, they can easily be recognized after dyeing because
polypropylene fibers do not absorb dyestuff (Fig. 10-21 and Fig. 10-22).
Fig. 10-21
10.12
Fig. 10-22
USTER QUANTUM 3
10
Bale management
Prefer when possible to use cotton with low content of foreign fibers.
Sometimes spinning mills tend to create or intensify the contamination
problem. A popular mistake is the use of plastic bags for the waste collection and transportation inside the spinning mill. Particularly the use
of polypropylene bags should be avoided.
Blowroom
Cards
Drawing frame
Combing
Table 10-2
Improvement
Quality control of foreign fibers with USTER TESTER when dealing with
new raw material
Proper setting of foreign fiber detection
Separate outlier bobbins with too many foreign fibers with quality alarm
settings
Long-term control of quality level
Table 10-3 Preventive measures and tools for the management of foreign fibers
USTER QUANTUM 3
10.13
10
10.14
USTER QUANTUM 3
11
11
Up to now, various smart features of the USTER QUANTUM 3 have been explained with the help of
different examples. At the beginning of this chapter, we would like to show the user some other smart
and helpful applications which can be used in various comparisons and data evaluations. The last
part of the chapter is focused on monitoring winding functions of the winding machine.
11.1
Selection of article
Article
Display of the
clearing limit from
2 other articles
Fig. 11-1
But there are also other usages. For example in Fig. 11-2, the comparison of two different settings of
the same article is given. Before editing the current article setting (Changed-Training/Test/30.0 NeC),
the user should make a copy of the article and give a different name. In this example, the new given
name is Training/Test/30.0 NeC and can be seen in C1 area. After the modifications of the current
article ' Changed-Training/Test/30.0 NeC, the user can detect the differences to the original settings
(dark blue line, C1) very easily: With the help of this comparison the user will not use any production
data and be switched to the original settings.
USTER QUANTUM 3
11.1
11
Fig. 11-2
Another application is the comparison of the current article to the chosen smart limit. In Fig. 11-3, the
original article settings are given as Curve 1 with dark blue color.
Fig. 11-3
11.2
USTER QUANTUM 3
11
Fig. 11-4
11.2
Recalling the factory settings of the default articles (capacitive (left)and optical (right))
11.2.1 Display of Data and Alarms with the help of bar graphs
With the USTER QUANTUM 3, it is possible to display the events occurring in the various evaluation
channels by using data bar graphs. These are used for monitoring quality and finding the outliers and
as aid for setting the clearing limits. There are various categories and related features and can be
found under the Display main menu, in the machine summary page. These categories and features
are given in Fig. 11-5.
USTER QUANTUM 3
11.3
11
Fig. 11-5
Machine summary categories and their features. Abbreviations: see Appendix, chapter 16.2.
Fig. 11-6
11.4
USTER QUANTUM 3
11
In Fig. 11-7, an example of these bar graphs is given. Here the category is Yarn Faults YF and feature is YF (see Fig. 11-5). As it can be seen on Fig. 11-7, every group has its own mean value which
is highlighted with a black horizontal line. The values can be displayed according to current data or
last shift. The user can also select relative or absolute display values. By using these bar graphs it is
very easy to compare various winding positions and find the outliers. However, because the scale is
changing automatically, the user should also check both the actual value for a winding position and
the mean value of the group before making decisions.
Red vertical line = selected winding
position (here SP 6)
SP = winding position (spindle)
(Totally 50 winding positions are in
production)
Black horizontal line = average value
of group
(Mean value for group
1 = 146.06 /100 km)
Gr.no. = group in production
(totally 3 groups are in production)
Fig. 11-7
11.2.2 Display of Data and Alarms with the help of exception reports
Another interesting and useful application is exception report. The user can define exception thresholds for the following event groups:
Yarn alarms YA
Quality alarms QA
Foreign fiber F
Faulty splices J
For the above mentioned event groups, the tolerances should be entered as +/- deviation in % of
group average value and/or events per 100 km or absolute number of events as upper tolerance limit.
In order to print out the values of all winding positions, Print all SP should be selected, otherwise
only the values of the exception winding positions will be printed out. The lines in the report with all
values = 0 will not be printed.
USTER QUANTUM 3
11.5
11
Fig. 11-8
Fig. 11-9
In the textile alarms submenu of the Display main menu, it is possible to display all yarn faults of
the machine, a group or a winding position over the selected period. The values for the machine, for a
group or for a winding position can be selected. Also various periods like current, current / last shift or
current / last article can be chosen and displayed. The "current" counter is reset with
Shift change
Article change
11.6
USTER QUANTUM 3
Fig. 11-10
11
All textile and technical alarms which have occurred during operation are displayed in the Alarms
function menu.
In the textile alarms window (Fig. 11-11, left), consecutive winding positions with the same alarm are
shown as a group. Textile alarms can be deleted either on the control unit or on the measuring head.
In the technical alarms and warnings window (Fig. 11-11, right), each individual alarm is displayed
with date and time and registered in the Service Logbook. Textile alarms and warnings can be deleted
on the control unit.
Fig. 11-11
Quality Alarm
USTER QUANTUM 3
Technical Alarm
11.7
11
11.3
Collecting defects
11.3.1 Introduction
To better understand defects Uster Technologies always recommends to put the fault on a black
board (disturbing thick and thin places) and on a white board (foreign fibers). To make this easier the
iMH-LED function can stop the winding position at a particular yarn defect type and the fault length,
percentage and classification can be displayed on the event report of the Central Clearing Unit.
Schlafhorst AC-338
Murata PC-21
Savio Espero
Savio Orion
Savio Polar
Smaro
The iMH LED display function can be assigned to the whole machine, one group or a range of winding positions.
When the programmed cut occurs:
The user should enter the range and cut type for the 3 display variants. These are:
11.8
USTER QUANTUM 3
Fig. 11-12
11
Fig. 11-13
USTER QUANTUM 3
11.9
11
Yarn fault cards have a white and a black side. For greige yarns the black side is used in order to
document yarn faults like thick and thin places. The other side, i.e. the white side of the yarn fault
card, is used for the documentation of foreign fibers and vegetable matter in the yarn. White polypropylene fibers should also be put on the black side. By this method, the yarn body disappears in the
background and the foreign fibers and vegetables can easily be recognized.
On top of the yarn fault card there is room for yarn, test and clearer identification. The information
about the clearing limits are of special importance in order to be able to compare the results of future
tests.
Depending on the application, the following decisions can be made with the aid of yarn fault cards or
they can serve to obtain more information:
with every modification of the clearing limits the expected cuts can be determined in advance
the quality of the current production can be controlled in accordance with textile aspects, i.e. with
respect to the form of the yarn fault
To sum up, it can be said that yarn fault cards with documented faults together with the classification
and the scatter plot serve as a basis to decide which clearer settings have to be chosen.
Fig. 11-14
When collecting thick places (e.g. N and S defects) it is quite easy to see the defects in the yarn. For
collecting the foreign fibers it is needed to use the white side of the board and make sure that there is
enough light so that the defect can be seen in the yarn easily. Sometimes it appears that the defect,
especially at low reflections e.g. 5 or 7% can hardly be seen under insufficient light conditions or even
need the aid of a magnifying glass to see it. Therefore the yarn board always should be used as support as shown in the examples, and, whenever possible, a magnifying glass. When the user has the
advanced classification option, then tailored classes can also be used to inspect yarn fault within a
length and amplitude range.
11.10
USTER QUANTUM 3
11.4
11
On most modern winding machines, the monitoring of the yarn joint process is carried out by the yarn
clearer. The functions of the clearer include the monitoring of the:
Splice (Joint, J)
Cut (CTM)
Fig. 11-15
Speed
Setting of the winding speed (for manual winding machines only).
Setting: Speed per group in m/min
Length correction
Correction factor to get correspondence between displayed and actual wound yarn length.
Setting:
The correction factor can be set for each group between 0.800 and 1.200 (+/- 20%).
The correction factor has no influence on the set reference lengths of the clearing channels.
Startup time
The start-up time must be set to measure the fault length correctly on a manual winder during the
start up acceleration. The start-up time represents the time between the winding position start until it
has reached the nominal speed.
Setting: 0.6, 1.2, 1.8, 2.4 and 3.0 s
USTER QUANTUM 3
11.11
11
ZPM
Zero point monitoring (ZPM): If, during the splicing cycle, there is still yarn or fluff in the measuring
zone despite the blow-out, then a ZPM event is counted but no zero adjustment made. Clean measuring zone.
CTM
Cut monitoring (CTM): If the iMH repeatedly detects running yarn after a cut then a technical alarm is
triggered. Check cutting device.
JPM
Yarn jump monitoring (JPM): A cut is triggered if the yarn jumps out of the measuring zone for a moment e.g. because of a large yarn fault.
JPA
Yarn jump alarm (JPA): A cut and an alarm is triggered if the yarn jumps out of the measuring zone 3
time per 1 km. The winding position is blocked and a textile alarm is displayed.
Possible settings for JPM and JPA:
Effect at yarn jump
JPM
JPA
Table 11-1
DSM
Drum signal monitoring (DSM): A technical alarm is activated if the iMH does not receive a guide
drum signal after the winding position starts up. Check guide drum sensor.
DWM
Drum wrap monitoring (DWM): DWM prevents the yarn from getting wrapped around the drum with a
cut.
11.12
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11
DWA
Drum wrap alarm (DWA): DWA prevents the yarn from getting wrapped around the guide drum with a
cut. At the same time a textile alarm is activated which blocks the winding position.
Dont cut drum wrap prevents loose pieces of yarn on ESPERO, ORION, POLAR, SMARO and
SPERO winder.
DWM
DWA
Dont cut DW
Espero, Orion, Polar, Smaro and Spero: Winding machine stops without cut.
Table 11-2
Fig. 11-16
USTER QUANTUM 3
11.13
11
11.4.1 Monitoring of the yarn joint process with the USTER QUANTUM 3
The monitoring of the yarn joint process by the clearer is carried out according to the splicing process
of the winding position (Please see Chapter 5). The individual steps are:
11.14
USTER QUANTUM 3
11
In order to make this procedure of the splice control easier, the USTER QUANTUM 3 splice classification was introduced. During the measurement, the values are recorded and displayed as a scatter
plot in the classification matrix (Fig. 11-17). The classifications of each single winding position can be
looked at separately, in order to be able to find the winding positions at which the splice formation
does not meet the quality requirements.
Fig. 11-17
USTER QUANTUM 3
11.15
11
JPA
If the function JPA is turned on, a textile alarm is triggered for every JPM-cut which blocks the respective winding position
11.16
USTER QUANTUM 3
11
DWA
The drum wrap alarm prevents the yarn wraps around the drum by a cut. At the same time, a textile
alarm is triggered which will block the winding position.
Our recommendation: Turn off function Drum wrap alarm DWA.
a double yarn cannot be recognized as such and thus, will be wound on the cone
a normal yarn cannot be recognized with the consequence, that a new cycle is started, although
no yarn is laid into the measuring zone.
USTER QUANTUM 3
11.17
11
11.18
USTER QUANTUM 3
12.
12.1
12
Fancy yarns are used in the textile industry for various applications. Therefore, fancy yarn manufacturing is not a niche market anymore. Up until now, it was not possible to determine the quality characteristics of fancy yarns in detail which are needed for a quality management. This can be done in
the laboratory with the USTER TESTER 5.
An accurate determination of slub yarn characteristics is also required for negotiations and specifications between fancy yarn spinners and weavers, knitters, traders and retailers.
12.2
Slubs, neps, thick and thin places are noted as yarn faults and are considered as degrading features
of yarn quality. During various processes, efforts are taken to minimize their occurrence. However, in
fancy yarn production these features are introduced in the yarn in order to give visually attractive differences to the other fabrics [1].
Fancy Yarn is a yarn that differs from the normal construction of single and ply yarns by way of deliberately produced irregularities from the normal construction. These irregularities relate to an increased
input of one or more of its components, or to the inclusion of random effects, such as knops, loops,
curls, slubs, or the like. [6]
There are various names which are used to describe the different yarn effects. Table 12-1 shows
eight basic profiles of fancy yarns. These yarn effects can be made by plying a number of yarns together or, with modified spinning techniques, most can be spun from sliver or roving [1].
Basic yarn profile
Designations
Spiral
Gimp
Slub
Ground slub, injected slub, injected flame (also called tear- off flame)
Knop
Loop
Cover
Twisted flame
Chenille
Snarl
Table 12-1 Various fancy yarns [1]
USTER QUANTUM 3
12.1
12
Fig. 12-1
There are also several classifications for fancy yarns. Table 12-1 gives one of these classifications
according to the employed production methods. Here mainly two production methods are employed:
Produced effects are based on twisting or doubling of yarns together to create the fancy yarn effect
from already spun yarns. Spun-effect yarns are fancy yarns spun directly from fibers fed to the spinning system [1].
12.2
USTER QUANTUM 3
12
Regular effects
Regular effects
Controlled
discontinuous effect
Spiral
Reverse caterpillar
Spiral
Button
Mouline
Neps
Mouline
Slub
Loop
Knots
Loop
Caterpillar
Boucle
Knop
Boucle
Combinations
Gimp
Slub
Gimp
Onde
Onde
Snarl
Chenille
Cover
Chenille
Table 12-2 Classification of fancy yarns [1]
If fancy yarns have to be cleared on winding machines, the following recommendations have to be
taken into consideration:
All the fancy yarns have a regular pattern (pseudo-random formation). If faults occur, the regular pattern is disturbed and can be recognized in the scatter plot (Yarn Body Clearing). Such faults can be
eliminated accordingly.
In this chapter we will concentrate mainly on slub yarns.
12.3
A slub yarn is a yarn in which slubs may be created to produce a desired effect. Generally, slub yarns
are divided into two classes: (i) spun slubs, and (ii) plucked (or inserted) slubs. Spun slubs may be
produced by an intermittent acceleration of one pair of rollers during spinning or by the blending of
fibers of different dimensions. Plucked slub yarns are composed of two foundation threads and short
lengths of straight-fiber materials that have been plucked from a twistless roving by roller action [6].
As the range of applications is very wide for slub yarns, there are also different types of slub yarns.
They are usually called slub yarns, multicount yarns and multitwist yarns.
USTER QUANTUM 3
12.3
12
Table 12-3 below explains the differences between these three yarn types.
Term
Twist
Mass
Slub length
Slub yarn
constant
variable
variable
Any length up to
2 meters
Multicount
variable
constant
variable
Multitwist
variable
variable
constant
any
It is also possible to distinguish between structured slub yarns and slub yarns with distinctive slubs.
Structured yarns can be characterized as very uneven yarns without any clear slubs. Fig. 12-2 shows
an example of a distinctive slub yarn on a blackboard.
Fig. 12-2
12.4
USTER QUANTUM 3
12
It is possible to assign up to 3 K areas where slubs should not be cut Fig. 12-3.
Fig. 12-3
12.4
The desired effect has to be monitored. If the effect is missing, a cut has to follow.
Fig. 12-4
USTER QUANTUM 3
12.5
12
In summary, it can be said, that all irregularities of the visual impression of the end product have to be
monitored.
12.5
Melange yarns
Melange yarns are produced by blending a certain percentage of fibers of different colors. Blending
can be done in a very early stage of the process. This means, for example, mixing of multi-colored
fibers in the opening line, feeding of slivers of different colors at the drawframe or directly at the spinning machine.
Fig. 12-5
Fig. 12-6
12.6
USTER QUANTUM 3
12.6
12
Core yarn
Core yarns are usually made of a filament core and a cover yarn made out of staple fibers. The main
problem with core yarns (with respect to yarn clearing) is the detection of the missing core. When a
core is missing, it causes a marginal change in diameter however it causes a higher change in mass.
The capacitive clearer has, therefore, an advantage for this application. The change in mass is proportional to the fineness of the core.
The USTER QUANTUM 3 has a new capacitive sensor technology which has an even better signal
ratio and therefore a higher possibility to detect the missing core. The detection is mainly possible
when the change in mass due to the missing core is higher than 5-6%.
Fig. 12-7
A missing core can only be detected if the mass of the core is at least 13% of the entire yarn mass.
USTER QUANTUM 3
12.7
12
12.8
USTER QUANTUM 3
13
13.1
Introduction
13
The USTER QUANTUM 3 is the successor of the USTER QUANTUM 2. With this new generation
of yarn clearers, the user has various smart tools in finding the optimum solutions in yarn clearing.
The new USTER QUANTUM 3 is focused on simplifying the complexities of yarn clearing and thereby enables the user to easily and fully exploit all clearer capabilities and to optimize production costs
every day. The USTER QUANTUM 3 interprets and displays the yarn characteristics in minutes and
proposes a starting position for clearing limits with a cut forecast by pressing a single button.
We have prepared this chapter as a quick reference for the setting of the most important features of
the USTER QUANTUM 3. This chapter is targeted on the one hand at new and inexperienced users
and, on the other hand, it is also relevant to everyone who is already experienced in yarn clearing and
would like to learn the new features of USTER QUANTUM 3.
We believe that with the combination of Uster Technologies know-how with smart, reliable and modern technology, the user will be able to deliver significantly better yarn quality and post spinning performance while most likely maintaining productivity.
13.2
This chapter is a quick reference for the setting of the most important features of the USTER QUANTUM 3. One page is dedicated for each feature (pages 13.4 to 13.16). The setting procedures are
shown graphically.
Setting a smart clearing limit for disturbing thick places (NSL) and thin places (T)
Page 13.4 shows the selection of the optimum clearing curve for thick and thin places. For a few seconds or minutes the yarn runs with the default clearing curve. After this period the operator can see
the yarn body on the screen. Now the clearing curve can be optimized either by moving the clearing
curve up or down. The setting can be fixed by pressing the confirm button.
USTER QUANTUM 3
13.1
13
Setting a clearing limit for foreign mater (FD) with Vegetable Clearing (VEG)
Page 13.7 shows the setting of the clearing curve for the Vegetable Clearing curve. With the setting of
the Vegetable Clearing curve there are opportunities to the lower number of cuts per unit length, because most of the vegetables cannot be seen after bleaching.
13.2
USTER QUANTUM 3
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13
13.3
13
13.4
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13
13.5
13
13.6
USTER QUANTUM 3
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13
13.7
13
13.8
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13
13.9
13
13.10
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13
13.11
13
13.12
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13
13.13
13
13.14
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13
13.15
13
13.16
USTER QUANTUM 3
14
14
This paper was written to answer the questions which are asked frequently by our customers.
14.1
14.1.1
USTER QUANTUM 3 offers the choice of optical and capacitive sensing technologies for basic clearing. The foreign matter option can be added on top of the basic capacitive or optical clearing.
The available measuring head types are:
Optical O30
*PP is an option to the C15F30, C20F30 and O30F30 measuring head see also 15-2.
14.1.2
The USTER QUANTUM 2 was until now the market leader and the benchmark for high performance
yarn clearing. The USTER QUANTUM 3, the successor, takes yarn clearing to a next level. The system was designed bearing the needs of a range of requirements starting from basic users to the most
sophisticated demands. It incorporates futuristic technology while at the same time being robust to
withstand the challenging mill environment.
The core of the USTER QUANTUM is its smart clearing technology. It helps to eliminate the basic
and most important challenge for spinners which is the definition of the optimum clearing limit for a
variety of yarns with differing quality needs. USTER QUANTUM 3 has simplified the complexities of
yarn clearing and enables valued users to easily and fully exploit all clearer capabilities, every day.
The system learns and displays the yarn body (nominal yarn with its set of tolerable frequently occurring yarn faults) in minutes and at the press of a button proposes a starting point for clearing limits
with a cut forecast. Practically this is equivalent to having an USTER specialist always beside to
achieve the optimum results out of any yarn application.
The new USTER QUANTUM 3 will also amaze you with its speed and ease of use. In just two
minutes, it will learn everything it needs to know about your yarn.
Then, applying USTER knowhow it will suggest the best way to achieve the quality requirements you
specify, by proposing suitable clearing limits. You now only need to approve and hit the START button
The USTER QUANTUM 3 with its new foreign matter clearing concept also sets a new benchmark
for contamination control.
The new sensor technology is able to see all colors of foreign fibers and separates them into disturbing foreign fibers and mostly non disturbing vegetables to enable maximum removal of foreign
fibers with minimal cuts.
Polypropylene detection is another key highlight. Founded on the new capacitive sensor technology,
USTER QUANTUM 3 sets a new benchmark for PP removal.
USTER QUANTUM 3
14.1
14
In summary the USTER QUANTUM 3 is the most robust and technologically advanced knowledge
integrated clearer ideally suited to todays market needs, far ahead of any competing products.
14.1.3
Display of the real yarn body to ensure appropriate clearing limits at the lowest possible cuts
Fast and easy setup of appropriate clearing limits - One button proposal for clearing limits considering the yarn body and requirements as a starting point for optimization
Easy selection of the appropriate clearing limit with open and close buttons
Detection and elimination of short term mass/diameter variations of length ranging from 2 m to
12 m having a major negative impact on fabric appearance
Scatter plot and numeric classification of splices to identify and eliminate rogue splicers. JRA
(splice failure ratio alarm) is a perfect feature to find rogue splicers.
New foreign fiber clearing concept separating foreign matter into foreign fibers and vegetable
matter. This allows the most effective and economic removal of disturbing foreign fibers ever.
Next generation of Polypropylene detection with a higher removal efficiency of PP including small PP
at high cut efficiency.
A new faster control clearing unit with the latest generation touch screen and an ergonomic interface
The next generation Expert system with a host of smart features The USTER QUANTUM EXPERT
3.
14.2
USTER QUANTUM 3
14.1.4
14
What are the new quality parameters measured by the USTER QUANTUM 3?
The USTER QUANTUM 3 detects short, fine thick and thin places in new classes see picture below.
Fig. 14-1
Short count variations (CC) of multiple cut lengths i.e. 2 m to 12 m (For comparison: USTER QUANTUM 2 only one cut length)
Periodic faults of multiple wavelengths
All colors of foreign fibers including those with very low contrast or reflectance
Fig. 14-2
USTER QUANTUM 3
14.3
14
14.1.5
What is the yarn count range of USTER QUANTUM 3 and which sensing method will
fulfill the quality requirement?
The USTER QUANTUM 3 yarn count range is extended compared to the USTER QUANTUM 2 and
can be used for all staple fiber yarns from Nec 3 Nec 200 / Tex 200 Tex 2.9. The choice of either
an optical or a capacitive sensor gives the widest application range. USTER will assist you in the
choice of sensing method best for your quality requirements.
14.1.6
USTER QUANTUM 3 comes with complete new sensor technology for all sensors including the optical basic clearing. The new optical sensor is able to see the complete yarn body and suggest clearing
limits for all applications.
In addition to the advanced short thick place detection, the system has new algorithms for detection of
long thick and thin places and also offers the new advanced count and CC channel to detect short
term diameter variations from 2 m to 12 m.
Splice clearing is taken to the next level with USTER QUANTUM 3 and the classification (numeric
and graphic) is offered with the new optical clearer.
As with USTER QUANTUM 2, Q Data monitors all quality parameters such as CV, Imperfections and
classification on the same basis as a the laboratory.
14.1.7
The USTER QUANTUM 3 separates foreign matter into three pools. It provides online classification
of foreign fibers (FD and FL) as before and for the first time Vegetable Matter Classification. Users
can see the amount of vegetables illustrated as dense areas or from the numeric vegetable classification matrix for different cotton varieties.
Another innovation is that the system provides a choice of four different clearing limit possibilities for
vegetables. With this the users can choose the level of vegetable clearing needed depending on the
end use.
14.1.8
The main problem with core yarns (with respect to yarn clearing) is the detection of the missing core.
When a core is missing, it causes a marginal change in diameter however it causes a higher change
in mass. The capacitive clearer has therefore an advantage for this application. The change in mass
is proportional to the fineness of the core.
The USTER QUANTUM 3 has a new capacitive sensor technology which has an even better signal
ratio and therefore a higher possibility to detect the missing core. The detection is mainly possible
when the change in mass due to the missing core is greater than 5-6%.
14.4
USTER QUANTUM 3
14.1.9
14
The USTER QUANTUM 3 clearing concept based on yarn body helps to easily define the boundaries for clearing disturbing defects in such yarns while retaining the slubs produced on purpose.
The K-point setting will easily help to keep these purposely produced slubs away from clearing. All
other defects, which might disturb the fabric appearance, can be taken out.
USTER QUANTUM 3
14.5
14
14.1.15 What is the purpose of the arrow LEDs on the measuring head?
The LEDs as in the case of USTER QUANTUM 2 are used to display textile or technical alarms. In
case of a textile alarm both arrows light up and in the case of a technical alarm both LEDs blink continuously
The arrow LEDs is also used in the test mode to collect defects. Each arrow LED can be programmed
for a specific fault type. Please refer to the operating instructions for more details about the several
possibilities with the test mode called the iMH LED function.
14.2
14.2.1
It depends on the type of application. Only Uster Technologies offers the knowledge and possibility of
the best capacitive and optical clearer for the monitoring and elimination of seldom-occurring thick
and thin places. Both types are available with the possibility of optical clearing for foreign fiber elimination. The sales staff and specialists of Uster Technologies can help you to select the best option for
your application.
14.2.2
With the USTER QUANTUM 3 Uster Technologies has developed a completely new, easy and customer oriented way of setting the clearing limits.
At first the system can be started up with existing clearing limits. After a couple of minutes of production, the USTER QUANTUM 3 analyzes the yarn and proposes smart clearing limits as a starting
point for optimization . The smart limits proposed consider the yarn body and the limits.
For each smart limit the system provides a forecast of the number of cuts to be expected.
14.6
USTER QUANTUM 3
14
In case the clearing limit proposal is not consistent with the end user requirements, users can choose
to open or close the setting easily with the open/close buttons or of course manually enter the settings.
14.2.3
How can one find the optimal setting for basic clearing? Is it the same as before?
With the USTER QUANTUM 3, finding the optimal setting is easier and faster like never before. After
evaluating the yarn over a few kilometers, the system proposes an optimum starting point for the
clearing limits considering the yarn body, experience and requirements. At the same time the system
predicts the number of cuts per 100 km to be expected for the defined limit. This is available at the
touch of a button.
In case the default starting point has to be changed for some reasons, users can simply choose from
a range of closer or more open limits each time looking at the cuts that should be expected for the
setting.
Thus the optimum setting is based on the smart limits within a short time
According to the quality level of the end user required, the settings can be selected more open or
close.
14.2.4
The best setting is a compromise between quality and productivity. The USTER QUANTUM 3 proposes an optimal starting point after a couple of minutes of production. This setting fulfils most end
user needs.
14.2.5
How can one find the optimum setting for good fabric appearance and for optimum
productivity?
The new unique feature of the yarn body display is showing the real characteristic of the yarn for the
first time.
After just 30 km of yarn running, the yarn body is illustrated and optimization can already be started. If
higher accuracy of cut prediction is sought one can wait for 100 km.
The smart limit proposal based on the yarn body analysis and USTER experience will ensure that
the clearing will result in no major defects left and good fabric appearance.
14.2.6
Which setting shall I use to make sure that no Classimat objectionable faults will remain?
The scatter plot and the yarn body are displayed according to the classes. The USTER QUANTUM 3
considers objectionable faults according to Classimat as a criterion when proposing clearing limits.
Where needed, the clearing limits can be easily adopted manually to ensure that no major defects will
remain in the yarn (to date).
USTER QUANTUM 3
14.7
14
14.2.7
The USTER QUANTUM 3 offers major advantages for compact spinners. Compact yarns are very
even, and small defects can be disturbing in the fabric. USTER QUANTUM 3 shows the complete
yarn body and hence it is possible to clearly identify and remove the outliers even if they are small
and fine. At the same time the unjustified cuts are minimized. Since yarn faults can easily be recognized by the human eye due to missing hairiness, the USTER QUANTUM 3 is particularly suitable to
detect small faults. Therefore the USTER QUANTUM 3 is the most powerful clearer for compact
yarns.
Trials with different compact yarn producers have shown that the fabric produced out of USTER
QUANTUM 3 cleared yarn is the best.
As known the monitoring of the quality parameters such as hairiness, evenness, imperfections and
periodic faults is also crucial with compact yarns. The USTER QUANTUM 3 with all these possibilities and the new periodic fault (PF) channel makes it much easier to find the fault reasons. The monitoring of the hairiness must be especially emphasized, as a higher hairiness variation results in a decrease of the yarn strength and cloudy fabric appearance.
14.2.8
Vegetables are part of foreign matter. However with most common bleaching processes, vegetables
disappear during bleaching. Therefore mostly it is not necessary to remove them. Imagine a clearer
without a vegetable filter in this clearer one would incur cuts for removing vegetables since the
clearer is not able to distinguish between vegetable and other foreign matter. Since the proportion of
vegetables are rather high in some cottons this results in a substantial drop in production and at the
same time limit the ability to remove real disturbing foreign fibers.
The USTER QUANTUM 3 intelligently separates vegetables from other foreign matter. This offers
better selectivity in F matter clearing and save cuts significantly. The reduction of cuts is reached by
allowing vegetables which will not disturb the downstream process to pass (they will not be cut). The
feature is used for articles that will go for bleached applications.
14.2.9
Why cannot all vegetables pass using Vegetable Matter Clearing when they are not
disturbing?
In most situations vegetables are not disturbing. However long and thick vegetables have to be removed since they can cause breaks in downstream processes.
In applications where the bleaching agents are milder, vegetables do not completely disappear after
bleaching and need to be treated as colored foreign fibers. Therefore they have to be removed according to the quality needs.
The built in intelligence of USTER QUANTUM 3 divides the vegetables into more or less disturbing
events according to the end product requirements. This is expressed by the way of setting close, medium and open setting.
14.8
USTER QUANTUM 3
14
14.2.10 We have an USTER QUANTUM clearer or other clearer generations - can we copy the
setting because it was acceptable until now?
The USTER QUANTUM 3 has a new easy way of setting which is nevertheless different from previous generations. Therefore, the same setting cannot be directly copied. However it is very easy to get
to the same or better quality and productivity levels by following the procedure below.
If the existing setting was fine until now, choose the smart limit in the USTER QUANTUM 3 which
offers the same level of cuts. This smart limit should normally be able to deliver the same or better
quality.
In a second step it is recommended to compare this setting with the yarn body itself to see if the setting follows the yarn body. If it does not follow the yarn body it is advantageous to choose a clearing
limit that follows the yarn body. On the other hand if the setting cuts into the yarn body it is beneficial
to stay away from the yarn body and save cuts.
Verify the results according to the normal quality. Make yarn boards to verify that all cut faults need to
be removed and that the not cut faults may remain.
14.2.11 What is different with the continuous count channel? Is the settings process easier?
With the USTER QUANTUM 3 the CC (continuous count) clearing has made a substantial jump. The
CC setting is now possible for multiple length channels.
To make settings easier the system displays the yarn body and an optimal starting point for the settings.
In a standard application a cut level for CC with about under 2.0 /100km is common.
If there is a problem occurring from side of the spinning process, e.g. sliver count deviations, the
clearer will identify these deteriorations and increase the cuts to ensure that only the yarn within the
given limits will be wound on the package.
USTER QUANTUM 3
14.9
14
14.2.14 What FD setting should I keep for a cotton yarn? (In case of no specific requirement
from the buyer)
An attempt should still be made to understand the quality demand of the end user to prevent claims
later.
As a general rule longer and very dark foreign fibers should be removed on priority.
We propose using the default smart limit setting of the USTER QUANTUM 3 together with the medium setting of the Vegetable Clearing in such situations.
Depending on the cuts and feedback from the buyer one might optimize the settings to more close or
open settings.
14.2.15 USTER QUANTUM 3 has more than 40 classes, but in USTER QUANTUM 2, we only
have 23 classes- What is the purpose of these additional classifications in USTER
QUANTUM 3?
Fig. 14-3
14.10
USTER QUANTUM 3
14
Fig. 14-4
The USTER QUANTUM 2 already offers extended classes in thick and thin places and extended
classification in Foreign Fiber classification.
USTER QUANTUM 3 offers these classes and further newer classes in thick and thin places with the
option Advanced Classification.
The new classes were defined due to the reason that yarns have become more even and defects in
these newly defined area have been seen to be causing quality claims. For the first time spinners can
measure and therefore control these defects.
14.2.16 USTER QUANTUM 3 has new sensor technology in basic and FM clearing are the
results comparable to the old classification?
The new sensor for the detection of thick places and thin places is able to better determine the length
and size of short thick places and the small thin places than the previous sensor. This more accurate
determination for short thick places does not affect the fault categories which have to be eliminated.
Foreign matter is detected by a sensor with multiple light sources which is able to deter-mine all colors with the same sensitivity because of improvements of the optical measuring system. However, the
counts per category remain within the statistical variations which have to be expected for seldom occurring events when comparing with the previous measuring systems.
USTER QUANTUM 3
14.11
14
For the capacitive clearer the combination with Foreign Matter option i.e. either C15/F30 or C20/F30
is required. There is a special setting on these clearers particularly assigned for the wet spliced applications.
Fig. 14-5
14.2.19 What are the experience values for cuts in ring spinning mills with foreign fiber
clearers?
Cuts will depend on the degree of contamination of the raw material and the quality requirements.
With medium degree of contamination of the raw material and non bleached fabrics end use it could
be expected that the foreign fiber cuts range between 10 to 40 cuts per 100 km. In case of bleached
knitted or woven fabrics FF clearing is more critical and even higher cuts should be expected.
With the new FF clearing concept, The USTER QUANTUM 3 ensures the highest possible quality
with the lowest possible cuts. The smart way of setting the clearing limits of the yarn clearer will ensure that the most disturbing fibers will always be eliminated first. Closer settings will eliminate finer
and shorter faults.
14.12
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14
USTER QUANTUM 3
14.13
14
14.14
USTER QUANTUM 3
Technical specifications
15
Technical specifications
15.1
15
Fig. 15-1
15.1.1 Architecture
The USTER QUANTUM 3 is a yarn clearing and monitoring system for winding machines consisting
of:
1. Central Clearing Unit 6 (CCU6). One control unit per winder. All settings and operational check of
each position are made from the Central Clearing Unit
- Standalone on all winders except Oerlikon Schlafhorst Autoconer 5 and X5
- Integrated with winder Informator on Oerlikon Schlafhorst Autoconer 5 and X5
2. Intelligent clearer measuring heads (iMH) for each winding position.
3. Interface to the winding positions and connecting cables.
For all spun yarns consisting of natural fibers, blended fibers, synthetic fibers and plyed yarns.
Languages:
Count range:
Maximum speed:
2200 m/min
USTER QUANTUM 3
15.1
15
Technical specifications
15.1.4 Miscellaneous
Printer:
Access Rights:
Unit system:
15.2
FEATURES
COMMENTS
N, S, L, T
C, CC
Jp, Jm
Splice Clearing
Cut forecast
Technical alarms
Textile alarms
Identification of vegetables
Polypropylene fibers
(Option)
Q-Data (Option)
Evenness (CV)
Imperfections
Class alarms
Basic clearing
Foreign
matter
Vegetable
Clearing
(Option)
15.2
USTER QUANTUM 3
15
Technical specifications
OPTIONS
Hairiness
(Option)
Expert (Option)
Advanced
Classification (Option)
Lab On-line
(Option)
Table 15-1
FEATURES
COMMENTS
Expert
Access to the data output for Expert System and centralized data collection and reporting
Extended Classes
Tailored classes
Software pack
FEATURES
Capacitive
C15
Capacitive Capacitive
C20
C15 F30
Capacitive
C20 F30
Optical
O30
Optical
O30 F30
BASIC
FOREIGN MATTER
(Option)
---
---
---
VEGETABLE (Option)
---
---
---
---
POLYPROPYLENE
(Option)
---
---
O*
O*
---
---
Q-DATA (Option)
HAIRINESS (Option)
---
---
---
USTER QUANTUM
EXPERT 3
---
---
---
Table 15-2
USTER QUANTUM 3
15.3
15
Technical specifications
Key:
X
Product Option Key (POK) is needed to have access to the feature mentioned in the header of this column
O*
Hardware upgrade required in the Central Clearing Unit 6 (CCU6) to have access to the feature
---
15.3
Table 15-3 shows the comparison capacitive versus optical measuring principle for basic clearing. In
the following table there are a few remarks to the selection of the clearer type.
OPTIONS
Capacitive principle
Optical principle
Basic difference
Sensitivity
A thick place with 3 times more fibers in the crosssection than average produces a signal of +73%
(Exception: N, S faults)
Application
range
Contamination
Exception 1:
Conductive
fibers
The capacitive system is affected by conductive fibers and should not be utilized for such
yarns
Exception 2:
Dyed yarn
Exception 3:
Wet splicing
Exception 4:
Wet spun linen
Not recommended
Table 15-3
15.4
USTER QUANTUM 3
Technical specifications
15.4
15
Winding machines
Table 15-4 shows the winding machines on which the USTER QUANTUM 3 can be used:
Manufacturer
New machines
Retrofit
Murata
Murata PC 21
Murata PC 21
Oerlikon Schlafhorst
Savio Orion
Savio Espero
Savio Polar
Savio Orion
Savio
Savio Polar
Qingdao
Qingdao Smaro
Qingdao Smaro
Table 15-4
15.5
iMH-C15
iMH-C20
iMH-O30
Option F30
Option PP
Nec 3
Nm 5
200 tex
Nec 6
Nm 10
100 tex
Nec 12
Nm 20
50 tex
Nec 30
Nm 50
20 tex
Nec 60
Nm 100
10 tex
Nec 80
Nm 135
7,4 tex
Nec 100
Nm 170
5,9 tex
Nec 200
Nm 340
2,9 tex
Fig. 15-2
USTER QUANTUM 3
15.5
15
15.6
Technical specifications
Subject
Architecture
of clearer
Characteristics
Technical specification
Intelligent measuring
head
Comment
Signal processing unit integrated in each measuring
head, no separate evaluation unit anymore, high
interference suppression, high accuracy due to the
self-check of the system.
Physical principles:
Mass variation:
capacitive
Diameter variation: optical
Length of measuring
zone: 2 mm
Physical principle:
Reflectance
Sensor for
Phase angle
polypropylene
detection
Sensor configurations
optical
Table 15-5
15.6
USTER QUANTUM 3
15
Technical specifications
15.7
Subject
Elimination
of disturbing thick
and thin
places
Quality
Abbreviation
characteristics
Short thick
places
Long thick
places
Thin places
Wrong bobbin
(count variation
during start up)
Elimination
of wrong
counts
Elimination
of periodical Periodical faults
faults
Dark foreign
fibers in light
yarns
Elimination
of foreign
fibers
Vegetable
material
Options
needed
Comment
0*/1...900%
0200 cm
Basic
0*/-1-100%
0200 cm
Basic
2...100 m
Basic
Cp
0*/+1...80%
Cm
0*/-1...-80%
CCp 1
0*/+1...+150%
CCp 2
0*/+1...+150% 12 m (default)
2 m (default)
Basic
CCm 1
0*/-1...- 80%
2 m (default)
CCm 2
0*/-1...- 80%
12 m (default)
PF
0*/50...100%
---
FD
0*/3...100%
0...10 cm
VEG
Polypropylene
fibers
PP
0*/3 100%
Avoidance of
thick joints
Jp
0*/-20+30%
Basic
Adjust to NSL
Avoidance of
thin joints
Jm
0*/-20+30%
Basic
Adjust to T
Jp
0*/1900%
010 cm
Basic
Jm
0*/-1-100%
010 cm
Basic
CY
0*/580%
Elimination
of bad joints Avoidance of
thick joints
Avoidance of
thin joints
Core
missing
NSL
Reference
length
Sensitivity
Core Yarn
0...10 cm
PP
Basic
Table 15-6
Abbreviation:
Q = Q-Data
F = Foreign fibers
USTER QUANTUM 3
PP = Polypropylene
0* = Inactive (off)
15.7
15
15.8
Technical specifications
The supervision of the machine operations depends on the requirements of the machine manufacturers.
Subject
Quality
Abbreviation
characteristics
Supervision
Avoidance of
of the splice
splice failures
failure ratio
Supervision
of upper
yarn during
joint operation
Avoidance of
double yarns
from the cone
side
Supervision
of the drum
wrap
Avoidance of
yarn wounds on
the guide drum
Sensitivity
Reference
length
Options
needed
JRA
0*/1100%
---
Basic
0*/10...200%
---
Basic
DWM
---
---
Basic
Comment
Table 15-7
0* = Inactive (off)
15.8
USTER QUANTUM 3
15
Technical specifications
15.9
All quality characteristics are monitored continuously at every production position. These quality characteristics can be monitored at any time.
Subject
Quality
characteristics
Abbreviation
Technical
specifications
Options
needed
Comment
Coefficient of
variation, per
group
CV-MV
50 ... 10'000 m,
0*/0.199%
Coefficient of
variation per
position
CV-SP
50 ... 10'000 m,
0*/1 99%
Imperfections:
IPI
Evaluation length:
502000m
Setting thresholds
frequent thin
places
-30/-40/-50/-60%
frequent thick
places
35/50/70/100%
frequent neps
140/200/280/400%
Length classes A to G:
0.2 1 cm, 1 2 cm
2 4 cm, 4 8 cm,
8 16 cm, 16 32 cm
32 64 cm, > 64 cm
Determination of
quality
characteristics
Classification of
thick and thin
places
CMT
Q, A
USTER QUANTUM 3
PF
N, S, L, T
Basic
Cp, Cm
Basic
15.9
15
Technical specifications
Quality
characteristics
Abbreviation
Technical
specifications
Options
needed
Comment
Count deviation
and monitoring of
uneven long thick
and thin places
CCp, CCm
FD
Length classes A to F:
0.1-0.6cm, 0.6-1cm,
1-1.4cm, 1.4-2cm, 2-3cm,
3-5cm, 5-7cm, >7cm
Subject
Classification of
foreign fibers
Reflectance classes:
5-7%, 7 10%, 10 20%,
20 30%, 30 100%
Foreign fibers,
grey or colored
yarns
FD
Polypropylene
fibers
PP
PP
Length classes A to F:
0.1-0.6cm, 0.6-1cm,
1-1.4cm, 1.4-2cm, 2-3 cm,
3-5cm, 5-7 cm, >7cm
Vegetable
clearing
VEG
Reflectance classes:
5-7%, 7-10%,
10-20%, 20-30%,
30-100%
Hairiness per
group
H-MV/
50 ... 10'000 m,
0*/0.1...20
Hairiness per
winding position
H-SP
50 ... 10'000 m,
0*/0.1...20
Measurement can be started at bobbin change or can be done continuously. The test length per bobbin can
be selected.
Splice classification
0...10 cm
-100900%
J-Classes as NSLT
Table 15-8
Abbreviations:
Q = Q-Data
= Hairiness
= Advanced Classification
F = Foreign fibers
PP
= Polypropylene
0*
= Inactive (off)
15.10
USTER QUANTUM 3
15
Technical specifications
Subject
Abbreviation
Settings
Reference
length
Options Comment
needed
Yarn fault
alarms
NSA
0*/1...99
1...999 km
Basic
LA
0*/1...99
1...999 km
Basic
Thin places
TA
0*/1...99
1...999 km
Basic
Wrong count
CA
0*/1...99
1...999 km
Basic
CCA
1...999 km
Basic
Foreign matter
FA
1...999 km
Polypropylene fibers
PPA
1...999 km
PP
Periodic faults
PFA
1...999 km
JRA
0*/1100%
---
Basic
upper:
0*/0.1...99%
0,05...10 km
Coefficient of variation
per position
upper:
0*/1...99%
0,05...10 km
0,05...10 km
0,05...10 km
(ALARM)
QRegistration
Q-Blocking
Q-Cut (Ejection)
Q-Blocking /
Sucking
0*/1...99
CV-SP
0*/1...99
0*/1...99
0*/1...99
lower:
0*/0.1...99%
lower:
0*/1...99%
Hairiness,
mean value of the
group
H-MV
H-SP
upper:
0*/0.1...20
lower:
0*/0.1...20
upper:
0*/0.1...20%
lower:
0*/0.1...20%
Special
Counters
Class Alarm
CMT
Up to 5 classes
Alarm limit
0*/1...64'000
1...300 km
Frequent neps
IP
0*/1...64000
0.05...10 km
IP
0*/1...64000
0.05...10 km
IP
0*/1...64000
0.05...10 km
0*/5900%
0.1200 cm
tT
0*/-5-100%
0.1200 cm
tFD
0*/5100%
0.110 cm
tFL
0*/5100%
0.110 cm
0*/10...200%
Machine-associated
---
Basic
Monitoring of the frequency
USTER QUANTUM 3
---
Basic
15.11
15
Technical specifications
Choices
Subject
Abbreviation
Settings
Reference
length
Options Comment
needed
additional cuts
Logbook
JPM /
JPM reg --/ JPA
---
Basic
DWM
DWM
reg
/DWA
---
---
Basic
DSM
---
---
Basic
Special cuts
SPC
---
---
Basic
Recording of all
changes and alarms
Logbook ---
---
Basic
Table 15-9
Abbreviations:
Q
= Q-Data
= Foreign fibers
= Hairiness
PP = Polypropylene
A
= Advanced Classification
0* = Inactive (off)
15.12
USTER QUANTUM 3
Technical specifications
15
15.11 Reports
Table 15-10 shows various reports. Reports can be transferred to an USB stick or to an optional
printer.
Per position
Per group
Display
Printout
Display
Printout
Necessary
options
Winding speed
---
---
---
Basic
Basic
Settings
---
---
Basic
Yarn
Faults
---
Basic
Basic
---
Basic
Basic
---
Basic
Basic
---
---
---
PP
Polypropylene fibers PP /
100 km
PP
---
Basic
Basic
---
Basic
Basic
---
Basic
Basic
---
Groups
Machine
data
Yarn Fault
Alarms
Yarn Fault
Alarms
Feature
USTER QUANTUM 3
Comment
List of reports:
Per shift, per
day, per article
Intermediate
report / present
shift
Last shift (can
also be configured as automatic report)
15.13
15
Technical specifications
Per position
Q Alarms
Printout
Display
Printout
Necessary
options
---
---
---
---
---
---
Basic
Exceptions: F, VEG, PP
---
---
---
---
---
---
---
---
---
Q, A
Classification of FD-faults /
100 km, absolute
---
Q, F
Classification of FL-faults /
100 km, absolute
---
Q, F
Classification of VEG-faults /
100 km, absolute
---
Q, F
---
---
---
---
**
**
**
**
Basic, F, PP
**
**
**
**
Other
**
**
**
**
Feature
Q Data
Event
reports
Per group
Display
Groups
Comment
Table 15-10
15.14
USTER QUANTUM 3
15
Technical specifications
Abbreviation:
Q = Q-Data
F = Foreign fibers
H = Hairiness
PP = Polypropylene
A = Advanced Classification
Available
Available if exceptions are defined and Print all SP (spindle positions) is selected in the menu Configuration- Exceptions.
** Available if events are defined and selected in the menu Configuration-Event report.
---
Not available
X*
Cellulosics,100%
Woolen
Worsted
Flax,linen, hemp
Spun Silk
O30/ F30
Optical,
O30
*PP option
C15/ F30
C20/F30
Capacitive
C15,C20
Table 15-11 shows the application range of the clearer types according to various yarn types:
Table 15-11
* For cotton yarns the polypropylene feature can be applied with clearer types C15/ F30 and C20/F30.
USTER QUANTUM 3
15.15
15
Technical specifications
The following tables shall give some guidelines what kind of iMH should be recommended.
The asterisks in the tables have the following significance:
***** Highly recommended
****
Recommended
***
**
Can be used for this application, but expertise of an Uster specialist recommended
Should not be used for this application without the expertise of an Uster specialist
---
Important note:
Guidelines for selling USTER QUANTUM 3: Most of our customers want to keep the type of sensors
which are installed on their machines because they may have achieved the best results with this type
of sensor. Therefore, it makes sense to continue with the same sensor principle.
Type of yarn
Cotton yarns
Count
range
Ne
All yarn
counts
1
Ply yarns
Blended
yarns
End use
IMH-C
IMH-O
IMH with F
Weaving / Knitting
*****
*****
*****
*****
*****
***
Different colors / 2
ply
*****
***
---
*****
****
---
*****
*****
***
*****
*****
***
Grey
*****
*****
***
Dyed
*****
***
***
All yarn
counts
15.16
Recommendation for
sales engineers
For all winders with wet
splicers (ask Uster specialists)
Detection of foreign fibers in ply yarns causes
more ply-joints
USTER QUANTUM 3
15
Technical specifications
Type of yarn
Melange
(Blended
yarns with
long staple
fibers of different colors)
Count
range
Ne
All yarn
counts
and
blends
End use
Core yarns
All yarn
counts
*****
IMH-O
*****
IMH with F
Recommendation for
sales engineers
****
**
***
****
*****
*****
*****
*****
---
***
*****
***
*****
****
****
***
Challenges depend on
the end use
***
---
DREF yarns
All yarn
counts
Slub yarns
All yarn
counts
Fancy fabrics
Antistatic
yarns, yarns
containing
metallic fibers
All yarn
counts
Technical fabrics
as well as safety
cloth
IMH-C
*****
---
*****
****
Linen, flax,
hemp yarns
***
*****
---
Linen
(wet spun)
---
*****
----
10
Spun silk
****
****
*****
11
Filament
yarns
***
***
---
Table 15-12
USTER QUANTUM 3
15.17
15
Technical specifications
15.13.2
The demand for detecting yarn count deviations is raising constantly. The conditions for the clearers
must be constant in order to guarantee the quality requirements. The choice of the correct measuring
system is very important. Especially when using the USTER QUANTUM 3 as a retrofit solution the
environmental condition plays a key role in order to exploit all the features of this clearer. Take into
consideration that the customer expects a better performance when changing to a new clearer.
Room conditions
IMH-C
IMH-O
IMH with F
****
*****
*****
**
*****
*****
***
*****
*****
Bad or no airconditioning
2
3
Table 15-13
15.18
USTER QUANTUM 3
Appendix
16
Appendix
16.1
Standard settings
16
The following standard settings should assist when setting clearer for short staple yarns and their
blends.
Fig. 16-1
Standard settings
USTER QUANTUM 3
16.1
16
Appendix
Fig. 16-2
16.2
Standard settings
USTER QUANTUM 3
Appendix
16.2
16
Abbreviations
A0...A4
Classimat classes
ADMV
B0...B4
Classimat classes
BC
Board Computer
BI
Built in
C0...C4
Classimat classes
CA
CC
CCA
CCm
(CC-) Lower tolerance limit for yarn count faults during operation
CCp
(CC+) Upper tolerance limit for yarn count deviations during operation
CCp1..2
CCU 6
Cm
(C-) Lower tolerance limit for yarn count faults during start-up
(m = minus)
CMT
CMTA
Cp
(C+) Upper tolerance limit for yarn count faults during start-up
(p = plus)
CSA
CSG
CTM
Cut Monitoring
CV
CVA
CV-MVAm
CV_MVAp
CY
Core Yarn
D0...D4
Classimat classes
DEF
DSM
DWA
DWM
DYD
USTER QUANTUM 3
16.3
16
Appendix
Classimat class
EHR
Foreign matter
F, P21 .. 22
Classimat classes
FA
FD
FD1... FD8
Setting Points for Foreign matter Dark (dark fiber in light yarn)
FL
FL1... FL8
Setting Points for Foreign matter Light (light fiber in dark yarn)
FMA
G, GP21 .. 22
Classimat classes
GR
Group
GUI
Hairiness
HA
Hairiness Alarm
H-MVAm
H-MVAp
H0...H2
Classimat classes
I0...I2
Classimat classes
iCSA
iMH
iMH-C
iMH-F
iMH-O
INF
Informator (Schlafhorst)
IPI
Imperfections
Jm
Jm1... Jm 8
Jp
Jp1... Jp 8
JPA
JPM
JR
JRA
K1...K3
16.4
USTER QUANTUM 3
Appendix
LA
LED
...m
Minus
MA
Machine
MMI
MV
Mean Value
NS
NSA
NSL
Very short thick places (N) and Short thick places and Long thick places
16
NSL1... NSL 8 Setting points for very short thick places (N)and Short thick places (NSL)
...p
Plus
P1...P8
Setting Points
PF
PFA
PP
Polypropylene clearing
POK
PPA
Polypropylene Alarm
PP1... PP 8
PROD
Q-Data
Quality data
SEED
SP
SPC
Special cut
SP-CTR
STAT
Status
SW
Software
SYD
Thin place
T1... T 8
TA
TB12
Classimat classes
TC12
Classimat classes
TD02
Classimat classes
USTER QUANTUM 3
16.5
16
Appendix
TM
Top Mounted
tNSL
tFD
tFL
tT
Upper Yarn
UQC
USTER QUANTUM 3
VEG
YA
YB
YD
Yarn Detector
YF
Yarn Fault
YJ
ZPM
Nec
Nm
tex
16.6
USTER QUANTUM 3
16
Appendix
16.3
Explanation of terms
Advanced classification
Article
Article change
Board computer
Bobbin
C-channel
Clearer
Clearer cut
Cutting of the running yarn to eliminate a disturbing yarn fault or a disturbing foreign fiber.
Clearer cut
blocking
Clearer group
See group
Clearing limit
Separation line between yarn faults which may remain in the yarn and
those which have to be cut by the clearer. The clearing limit is defined by
the setting of the sensitivity and the reference length for the respective fault
channel.
For the setting of the fault channels, the clearing limit is shown in the display of the USTER QUANTUM 3 unit.
For technical reasons, the clearing limit is subject to a certain tolerance.
CMT matrix
Cone
Central Clearing
unit
Cross-sectional
deviation
Cut forecast
USTER QUANTUM 3
16.7
16
Appendix
Dense Area
Diameter deviation
Display
Double thread
Extended classes
Evaluation unit
Fault channel
Group
iMH intelligent
measuring head
Interface
L-channel
Lab On-Line
Machine computer
Mass deviation
Material
Measuring field
16.8
evaluation of the yarn signals for the yarn fault detection, provided by
the measuring head
issue of a cut command to the measuring head (or the winding machine) in the event of a disturbing yarn fault
signal exchange with the winding position, e.g.: cut blocking, electronic yarn detector, etc.
The yarn faults are detected according to the reference length and the sensitivity in different fault channels.
(setting group, clearer group) Consecutive number of spindles which have
- the same measuring head type
- producing the same yarn and use the same settings
Electrical signal consisting of a pulse sequence. The pulse frequency is
equivalent to a multiple of the circumferential speed of the guide drum. The
guide drum signal is used, among other things, for the calculated adjustment of the fault reference length to the yarn count.
Part of the USTER QUANTUM. Some of the functions are:
- conversion of the yarn mass or yarn diameter in a proportional electrical signal
- evaluation of the yarn signals for the yarn fault detection, provided by
the measuring head
- issue of a cut command to the cutter (or the winding machine) in the
event of a disturbing yarn fault
- signal exchange with the winding position, e.g.: cut blocking, electronic
yarn detector, etc.
Permits the exchange of data between different systems.
Fault channel for the detection of long thick places.
Software pack consists of Hairiness, Advanced Classification and Expert.
See board computer
Deviation of the yarn mass from the mean yarn value.
Raw material of the yarn. Material in pure form or as a blend of different
materials used for the production of yarns.
Part of the measuring head which converts the yarn measurement into an
electrical signal.
USTER QUANTUM 3
16
Appendix
N-channel
Nep
OEM
Periodic Faults
Reference length
Release
Reset
Fault channel for the detection of very short thick places or neps.
Thick place which is shorter than 1 cm.
OEM = Original Equipment Manufacturer
The USTER QUANTUM 3 installation is delivered to the customer by the
machine manufacturer who acts as OEM partner for Uster Technologies.
Detection of periodic faults at multiple wave length.
Set length over which a clearing feature is evaluated.
See software release
Resetting an electronic circuit to a preset initial state.
Retrofit
Scatter plot
S-channel
Sensitivity
Smart limits
Software pack
Software release
Spinning cop
Splice
Splice check
T-channel
Tailored classes
Thick place, long
Thick place, short
Vegetable Clearing
USTER QUANTUM 3
Check the yarn drawn from the package during splice cycle. Prevent from
joining two or more yarns from the package to the yarn from the bobbin
(lower yarn).
Separation of vegetable matter.
16.9
16
Appendix
Winding position
Yarn body
Yarn clearing
Yarn fault
Yarn fault channel
Yarn fineness
Yarn measurement
value
Yarn joint
16.10
Winding unit of a winding machine, which winds the yarn of several bobbins
to a cone.
The yarn body is defined as the nominal yarn with its tolerable, frequent
yarn faults.
The detection and removal of disturbing yarn faults.
Faulty yarn section which is detected by the yarn clearing. Collective term
for all thick and thin places.
See fault channel.
(Yarn count) System of units for yarn:
Nm, Nec, New
Ratio: Length/mass
Tex
Ratio: Mass/length
USTER QUANTUM 3
Appendix
16.4
16
Unit
Abrevation
Length
Meter
Mass
Kilogram
kg
Time
Second
Electric current
Ampere
Temperature
Kelvin
Amount of substance
Mole
mole
Intensity of light
Candela
cd
USTER QUANTUM 3
Table 16-1
Seven base units
16.11
16
Appendix
With the SI-system, there are two special properties which are to be given preference:
In the SI-system, the derived units are coherent, i.e., all derived units are a combination of basic
units in which only the numerical factor 1 is encountered.
The SI-system is characterized by 'freedom from contradiction', i.e., every physical size can only
be described in one manner with the help of the basic units.
The units allowed and those which are obsolete when applying the SI-system for fiber, sliver, roving
and yarn testing are summarized in the following table:
Physical parameter
Conversion
Obsolete units
km, cm, mm
1 m = 1,099 yard
kg/m
ktex, tex
(1 ktex = 1 g/m)
(1tex = 1 g/km)
1 tex = 1000/Nm
1 tex = 590,5/Nec
kilogram
kg
g, mg, g
1 kg = 2,204624 lbs
Newton
mN, cN
1N = 0.102 kgf
Newton/tex
N/tex
cN/tex
Newton meter
(Joule)
Nm
cN cm
1 cN cm = 0.9807 gf cm
1 N m = 0.09807 kgf m
g cm, kg m
Base unit
Abbreviation
Derived units
meter
kilogram/meter
Mass
Force
Length
Length-related
mass
Tenacity
Work done
Table 16-2
Unfortunately the textile industry still uses obsolete unit systems. The following tables are conversion
tables.
16.12
USTER QUANTUM 3
Appendix
16
590.5 590.5
=
= 18.45
Ne c
32
Metric
tex
dtex
den
grains
yard
tex
dtex 0.1
den 0.111
grains
70.86
yard
dtex
tex 10
den 1.11
den
tex 9
dtex 0.9
tex
70.68
g
inch
g
inch
Nm
Nec
Nel
New
Y.S.W.
g
inch
25.4
1'000
Nm
590.5
Ne c
1653.5
Ne l
885.8
Ne w
1937.7
Y.S.W.
grains
708.6
yard
g
inch
2.54
10'000
Nm
5905.4
Ne c
16'535
Ne l
8858
Ne w
19'377
Y.S.W.
grains
637.7
yard
g
inch
2.82
9'000
Nm
5314.9
Ne c
14'882
Ne l
7972.3
Ne w
17'439
Y.S.W.
dtex
708.6
den
637.7
g
inch
1801.4
14.1
Nm
8.33
Nec
23.33
Nel
12.5
Ne w
27.34
Y.S.W.
tex 25.4
dtex 2.54
den 2.82
grains
1801.4
yard
25'400
Nm
15'000
Ne c
42'000
Nel
22'500
Ne w
49'218
Y.S.W.
Nm
1'000
tex
10'000
dtex
9'000
den
14.1
grains
yard
25'400
g
inch
Nec 1.693
Nel 0.605
New 1.13
Y.S.W.
0.516
Nec
590.5
tex
5'905.4
dtex
5314.9
den
8.33
grains
yard
15'000
g
inch
Nm
1.693
Nel
2 .8
Ne w
1 .5
Y.S.W.
3.28
Nel
1'653.5
tex
16'535
dtex
14'882
den
23.33
grains
yard
42'000
g
inch
Nm
0.605
Nec 2.8
New 1.87
Y.S.W.
1.172
New
885.8
tex
8'858
dtex
7972.3
den
12.5
grains
yard
22'500
g
inch
Nm
1.13
Nec 1.5
Nel
1.87
Y.S.W.
2.187
Y.S.W.
1'937.7
tex
19'377
dtex
17'439
den
27.34
grains
yard
49'218
g
inch
Nm
0.516
Nec 3.28
Nel 1.172
New 2.187
grains
yard
English
Metric
English
TO DETERMINE
GIVEN
Table 16-3
USTER QUANTUM 3
16.13
16
Appendix
Decitex
Nec
den
Denier
Nel
g/inch (approx)
New
Nm
Metric count
Y.S.W.
Length units
Area units
Mass units
Force units
Tenacity
Symbol
Metric unit
1 inch
in
2.54 cm
1 foot (= 12 in)
ft
0.3048 m
1 yard (= 3 ft)
yd
0.9144 m
1 mile
mile
1609.344 m
lea
109 m
hank
768 m
1 square inch
sq in
6.4516 cm
1 square foot
sq ft
929.030 cm
1 square yard
sq yd
0.836127 m
1 square mile
sq mile
2.58999 km
1 grain
gr
0.064799 g
1 ounce
oz
28.3495 g
1 pound
lb
0.453592 kg
1 gram-force
gf
0,0098 N
1 ounce-force
ozf
0.278014 N
lbf
4.44822 N
1 kgf Nec
0.579 cN / tex
1 kilogram-force Nec
1 gram-force per denier
Pressure units
1 gf / den
2
2
2
8.838 cN /tex
2
6894.76 N/m
47.8803 N/m
lbf/in
lbf/ft
Table 16-4
16.14
USTER QUANTUM 3
Appendix
16.5
16
Bibliography
1.
Lawrence, C.,A., Fundamentals of Spun Yarn Technology, CRC Press LLC, 2003.
2.
Lord, P. R., Handbook of Yarn Production: Technology, Science and Economics, Woodhead
Publishing Limited, 2005.
3.
Schindler C., ITMF COTTON CONTAMINATION SURVEY 2007, 29th International Cotton Conference, Proceedings, Bremen, April 2 - 5, 2008.
4.
5.
6.
The Textile Institute Textile terms and definitions 8th Edition, Manara Printing Services, London,
1986.
7.
USTER QUANTUM 3 Operational Handbook: The yarn quality assurance system -Winding,
316 052-10010, December 2010.
8.
USTER QUANTUM 2 Application Handbook: On-line quality management on winding machines, V2.2, 304 000-89720, December 2008.
9.
USTER TESTER 5 Application Handbook: Laboratory system for the measurement of yarns,
rovings and slivers, V1.3, 410 106-04020, December 2008.
10.
USTER News Bulletin No 47: Origins of fabric defects and ways to reduce them: Recommendations for Spinning Mills, July 2010.
11.
USTER News Bulletin No 45: Think Quality: Opportunities to improve the quality in the textile
supply chain, July 2008.
12.
USTER CLASSIMAT QUANTUM Application Handbook, Classification of thick and thin places, classification of foreign fibers, V1.1, 304 100-89720, May 2005.
13.
14.
USTER ZWEIGLE SPLICE TESTER 4 Application Report: Determination of the strength and
elongation of splices, SE 633, February 2010.
15.
16.
Behery H., Thomas, R.K.T., Understanding the Short Staple Manufacturing Process and the
Sources of its Yarn Faults.
USTER QUANTUM 3
16.15
16
16.16
Appendix
USTER QUANTUM 3
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