USTER® QUANTUM 3
The yarn quality assurance system
Application Training
Basics of yarn clearing
Capacitive versus optical signal
Yarn Yarn signal Yarn signal
(capacitive) (optical)
iMH C15 or C20 iMH O 30
A capacitive measuring An optical signal is propor-
Basic difference tional to the diameter of a
signal is proportional to
the mass of the cross- yarn
section of a yarn
Regular yarn
0% base value 0% base value
Thick places
with double cross-section Increase of cross-section: +100% Increase of diameter: +42%
Thin place
Decrease of cross-section: -50% Decrease of diameter: -29%
with half of the cross-section
2
USTER® QUANTUM 3
YARN BODYTM for NSL T channel
Same yarn - different sensor type
Capacitive
C15F30
Optical
O30F30
3
USTER® QUANTUM 3
New sensor technologies
Capacitive sensor
UQ2 C15 iMK captures less minor neps than UQ3 iMH C15 does
because of measuring field length
4
Basics of yarn clearing
Claims and their origin
Remaining Contamination;
thicks/thins; 16% 14%
Fabric Barré; 13%
appearance;
15%
Hairiness –
pilling ; 12%
Breaks in knitting
/ weaving; 21% White
specs; 9%
5
Basics of yarn clearing
Definition
Yarn clearing is replacing a disturbing defect
with a less disturbing splice
This means :
– Cut only where it improves quality or performance in downstream
processes
– Make sure that the splice is better than the defect taken out
USTER® QUANTUM 3 is focused on helping customers easily
achieve this basic objective
6
USTER® QUANTUM 3
The clearing cycle
Quick optimization Assess the
with Smart Limits cleared yarn
Uncleared yarn Cleared yarn without
disturbing yarn faults
Manual fine
tuning of
clearing limits
7 UQ 3 Service training SEA January 2015
Basics of yarn clearing
Limits of yarn clearing
• Yarn clearing is always a compromise between replacing a defect by a
splice and the loss of efficiency of the winder
• Even if the splice quality is equal to the yarn every cut will cause a stop
of the winding position
• An increase of winding speed to compensate the loss of efficiency will
mostly influence the yarn characteristics
• Basic quality improvement can be achieved mainly by controlling faults
generation through optimizing the spinning process and better house
keeping and not by increasing the cuts level
8
Basics of yarn clearing
Basic rules of yarn clearing
• There is no ring spun yarn without showing any defect
• Start always with an open setting and compare how the setting fits to
the YARN BODYTM
• If there is no cut over the last 1000km, the setting might be too open
• If there are too many cuts, either the setting is too close or the spinning
process needs to be controlled in a better way
• If all positions have an evenly high level of Jp cuts the splice setting
has to be controlled and if needed or the clearing limit has to be
opened if it is closer than the distribution of splices is located
• Jp setting always adjust to NSL T, except for special applications
• If I have an exception, the bad part is on the package, only if the same
bobbin is giving a 2nd or 3rd time the same cut
9
Basics of yarn clearing
Basic rules of Foreign Matter clearing
• There is no golden rule for FD setting, this depends strongly on the
end product requirements
• Vegetable Matter clearing is only recommended if the cotton yarn will
be used for bleaching later on
• PP setting should not be set below 7% for starting the optimization
process
10
Defining clearing limits – Basic approach
The approach here is valid for limits for all defect types understand the
normal yarn variations and define limits sufficient to eliminate exceptions
Too open
Mass or diameter variation
Optimized
Too close
Optimized
Too open
Length
Note: Diagram for illustration purposes only
11 UQ 3 Service training SEA January 2015
Basics of yarn clearing
The target of yarn clearing is to eliminate outliers
Fault frequency
Clearing limit, to be defined
by the customer
0%
- 100% Mean value + 100%
Area of the frequent yarn faults Area of seldom-occurring yarn faults
(CV, Imperfections, Hairiness)
Data measured in the Laboratory Monitored by QUANTUM 3
Defective bobbins are eliminated Replaced by a splice
12
USTER® QUANTUM 3
YARN BODYTM
Definition
The YARN BODYTM is composed of two parts:
• Dark green area representing the real YARN BODYTM
• Light green area representing YARN BODYTM variations
13
CLASSIMAT
defects Classification
Ring front zone dirty, fly Floating fibers, fly, slub More fluff in ring
waste in trumpet etc. Slub from ring department etc., department
(Unacceptable faults) (Unacceptable faults) (Unacceptable faults) (Unacceptable faults)
Neps, Fluff, foreign
matters, dirty drafting Fluff in travellers, unsuitable Ring piecing etc., More fluff in ring dept.
zone travellers, bad piecing (Unacceptable faults) (Unacceptable faults)
roving distance, spacer
Bad condition of carding, Fibers damage in process, Bad piecing in cans, sliver problem (Unacceptable
blow room, trash in yarn spindle without aprons entanglements etc., faults)
Bad condition of carding, Fibers damage in process, Bad piecing in cans, sliver Double yarn
blow room, trash in yarn spindle without aprons entanglements etc., Floating Fibers (Spinners Double)
Bad piecing in Bad piecing in
ring, roving & ring, roving &
back process back process
etc., etc.,
Mostly eccentric Separation of
bobbins of sliver or roving
simples & ring, prior to spinning
ring eccentric
spindles etc.,
Poor handling Separation of
of material sliver or roving
during prior to spinning
processes
14 UQ 3 Service training SEA January 2015
USTER® QUANTUM 3
Smart Clearing TechnologyTM
Definition
• YARN BODYTM Display
– NSL T
– CC
• Dense Area
– FD/FL
– Vegetable
• Scatter Plot
– PP
– Jp/Jm
15
USTER® QUANTUM 3
Smart Clearing TechnologyTM
Benefits regarding quality
Quality
• Smart Clearing TechnologyTM proposes limits based on the
YARN BODYTM thus preventing wrong settings
• The spinner can improve yarn quality by focusing on removing
faults which are really disturbing on fabric appearance
• By using Smart Clearing TechnologyTM open or close setting
buttons the spinner can easily set his own performance standards
16
USTER® QUANTUM 3
Smart Clearing TechnologyTM
Smart Limits based on YARN BODYTM
• The Smart Limit function proposes a starting point for the clearing limits based
on the YARN BODYTM, USTER knowhow and CLASSIMAT classes
• The system also provides a cut forecast to facilitate faster setup of clearing
limits
Open setting Close setting
17
USTER® QUANTUM 3
Optimized settings with Smart Clearing TechnologyTM
Practical examples for optimizing NSLT setting
China, 90% cotton/10% PES, Ne 40/1, carded, knitting, 1500 m/min
Small adaptations will help to reduce the cuts using the Smart limit function
Before optimisation After optimisation
18
Practical examples for NSLT setting
Too many cuts as a result from ring spinning might lead to open
settings. The YARN BODYTM will help to prevent this.
Old
setting
New
setting
19
USTER® QUANTUM 3
Display of different clearing limits
CC
NSL T
20
USTER® QUANTUM 3
Practical example for setting of C
If there is no cut the setting is too open
21
USTER® QUANTUM 3
Practical example for setting of C
C reference length recommended to be 8 meters
22
USTER® QUANTUM 3
Practical example for setting of CC
The CC setting should be balanced between 2 and 12 meters
This setting is very close to the YARN BODYTM at 2,0 meter
reference length, but for 12,0 meter the setting is too open
and not following the shape of the YARN BODYTM.
23
USTER® QUANTUM 3
Splice clearing easy adjustment to NSLT
The clearing limit should not be set closer than the splice limit
24
USTER® QUANTUM 3
Outlier positions might result from bad yarn or
Mechanical problems on the winding position
Identify winding positions with high level of Jp cuts
Let the mechanics check these position
25
USTER® QUANTUM 3
FD detection with multi colored LED
Screen Comment
Function
Detection of foreign fibers by
analyzing the reflection
differences to the yarn, using
two different LED-colors
Impact
All contaminants starting from
2mm length and more than 3%
reflection can be classified,
counted and compared to the
clearing limits
26
USTER® QUANTUM 3
FD detection with multi colored LED
Example of clearing limits
27
USTER® QUANTUM 3
New sensor technologies
Vegetable Matter clearing
Improved C-Sensor in combination with the unique Foreign Matter
Sensor is base for a new generation of Vegetable Matter clearing.
• Separation between Foreign Fibers and Vegetable Matter
• Classification of vegetables
28
USTER® QUANTUM 3
Vegetable Matter Clearing
Example Ne 40, 100% cotton, combed yarn
Foreign Fibers and Vegetables
Foreign Fibers and Vegetables only Vegetables
29
USTER® QUANTUM 3
New sensor technologies
Polypropylene detection
Multicolored
light sources
in the FM
sensor
New
capacitive
sensor
technology
Major jump in
PP detection
30
USTER® QUANTUM 3
PP Clearing
hints for optimisation
PP efficiency on yarn board
– With UQ 3 the efficiency is mainly above 60% efficiency
– We can not go much closer than the variation of the noise level
– As too short reference length might lower efficiency
31
Total contamination control from USTER
The most advanced systems at the opening and finishing stages offer the
greatest removal capabilities while limiting waste
USTER® JOSSI VISION SHIELD USTER ® QUANTUM 3
• Market leader in fibre cleaning systems • Sensors with multicolored LEDs to detect all
• High detection efficiency due to latest colors of contaminants
optical microchip generation • Highest detection rate of single short and
• Multiple integrated detection systems for long polypropylene fibers
eliminating all kind of contamination • Possibility to filter non disturbing vegetable
• Minimum loss of good cotton per ejection matter (not to cut)
• Low maintenance rate • Visual illustration of foreign matter density
and classification of foreign fibers to assess
overall raw material contamination levels
32
Periodic defects
To be detected by the yarn clearer
33
USTER® QUANTUM 3
Periodic yarn fault detection
• USTER® QUANTUM 3 has a special designed functioned named periodical
fault.
• With the setting of sensitivity the minimum limit of mass increase is selected by
the customer, depending on the end use of the yarn.
• For every individual spindle it is using the classification of the single event and
will put it in an internal classification.
• The number of periods is the number of events of this comparable size which
have to be registered to be in a periodical distance.
• If this rule is fulfilled the distance between these events is of a high periodicity
the clearer will cut and suck down the defective length from the package.
• On the event report, as configured to display PF events, it will show the
average size of the distance, the sensitivity level as well as the periodicity of
these events.
34
USTER® QUANTUM 3
Periodic yarn fault detection
- The PF channel will detect periodical defects coming in a periodical sequence
and are of about the same dimensions.
- Customers should be informed that the PF setting was changed from regularity
setting to sensitivity setting starting with 1.10.11 and needs to be set different
than before.
- The setting of PF is defining the minimum amplitude at 1,0 cm defect length.
As a rule of thumb it can be recommended to use 2.5 times CVm%
- Regarding the maximum distance between the defects, there is not a fixed
length, this is depending on the significance as well as the length of the
defects.
35
USTER® QUANTUM 3
Q-Data
36
USTER® QUANTUM 3
Q-Data function & Smart limit
CVm%
Screen Comment
Function
2 new functions on the setting
page:
Display values
Smart Limit
Impact
The Smart limit button will
propose a setting for quality
limits
37
USTER® QUANTUM 3
Q-Data function
Blocking after n repetitions
Screen Comment
Function
Register
Cut
Suction
Blocking
Impact
This setting will define after
how many occurrences in a
row the blocking will take
place, to take out the bobbin.
The suction can be activated or
not in this modus.
38
USTER® QUANTUM 3
Data Display
Smart Summary Screen
Smart Summary Screen Comment
Function
With the easy access buttons
a shortcut to the favorite charts
can be easily done
Impact
generate a shortcut
to this screen
delete the shortcut
39
USTER® QUANTUM 3
Status of IMH
40
USTER® QUANTUM 3
Special Functions
IMH LED Function
IMH LED Function Comment
Function
Stop a defined number of
positions after a occurrence of
a defined defect.
Impact
Up to 3 different defect types
can be selected and defects
can be collected
simultaneously
41
USTER® QUANTUM 3
Special Functions
Extended classes
Extended classes Comment
Function
Extended classes are used
mainly for even yarn types like
compact yarn, Siro spun yarn
or plied yarn
Impact
Beside the standard classes
another 18 classes become
available
42
USTER® QUANTUM 3
Unique package for total quality – Tailored classes
Tailored Classes Settings – Users can
easily define their own fault classes!
43
USTER® QUANTUM 3
Special Functions
Textile alarm
Textile Alarm Comment
Function
The textile alarm will identify
bobbins having too many cuts
of a certain type within a given
length
Impact
By setting a textile alarm, e.g.
10 per 1km, the bobbin will be
stopped if the set limits are
overstepped. The defective
bobbin can be taken out of the
production process for further
analysis in the laboratory.
44
USTER® QUANTUM 3
Special Functions
Copy to USB
Textile Alarm Comment
Function
An article defined on a CCU
can be copied to the USB
device and reloaded to other
CCU
Impact
If an article is defined on one
CCU it can be easily installed
on any other CCU were the
same article is about to run.
45
USTER® QUANTUM 3
Practical part
collect samples violating alarm limits
46
USTER® QUANTUM 3
Practical part
Finding solutions
47
USTER® QUANTUM 3
Application range
Selection of clearer type Comment
Count range Ne 3 until Ne 200. Function
For capacitive clearer two
different measuring heads are
available named C15 (C15F30)
and C20 (C20F30).
Impact
If both clearer types are
possible, according to the
count range, generally the C 20
(C20F30) is recommended.
However we encourage
contacting your local Uster
technical specialists for
guidance specific to your mill
and application.
50
USTER® QUANTUM 3
winding machines
New deliveries Retrofits
• Schlafhorst AC X5 • Schlafhorst AC338
• Murata PC 21C • Schlafhorst AC X5
• Murata PC II Q PRO • Murata PC 21C
• Savio Polar • Murata PC II Q PRO
• Savio Orion • Savio Polar
• Qingdao Smaro • Savio Orion
• Qingdao Spero • Savio Espero
• Qingdao Smaro
• Qingdao Spero
51
USTER® QUANTUM 3
Special Functions
Colored yarn in combination with optical clearer
O-Single-Adjustment Comment
Function
O-Single-Adjustment is to be
used only on colored yarn
using the optical sensor
Impact
On O-Single-Adjustment every
clearer will generate its own
startsum to avoid an impact of
color shade variation on the
diameter reading
53
USTER® QUANTUM 3
Special Functions
FL Colored yarn
54
USTER® QUANTUM 3
Special Functions
FL Colored yarn
FL-Setting Comment
Function
FL is designed for detection of
light foreign fibers in dark
colored yarn
Impact
The setting of FL is working the
same way like the FD setting.
The yarn itself has a stronger
color than the contaminant.
55
USTER® QUANTUM 3
Special Functions
FL + FD in parallel for colored yarn
56
USTER® QUANTUM 3
colored yarn single color as well as mélange
What is important for FD, FL setting
• Stop/Start the article
• Use the yarn without defects to generate at least 10 – 20
start-ups.
• Run about 20 km to get the FD as well as FL dense area.
• Assign a clearing limit not too close to the dense area in the
beginning
• Collect some FD and FL defects along with their dimensions
before going closer with the settings
Sometimes customer will only supply a bobbin with lots of
defects without enough material for ADMV generation
Some customer manipulate bobbins with defects every
one meter, which will also generate problems for
adjustment
57 UQ 3 Service training SEA January 2015
USTER® QUANTUM 3
FL setting
Proper clearing limits are the key
58
UQ 3 Mélange yarn clearing
Color differences
single events FD / FL
Normal Yarn Colored / Mélange
FD
FD only
FL
59
USTER® QUANTUM 3
Mélange yarn
60
USTER® QUANTUM 3
Mélange yarn
Potential risk of color mix up
61
USTER® QUANTUM 3
Special Functions
Wet spliced in combination with capacitive clearer
Wet spliced Comment
Function
For capacitive clearer with
foreign fiber detection like
C15F30 or C20F30.
Impact
The wet-splice will be
controlled by the light of the FD
sensor and not by the
capacitive sensor
62
USTER® QUANTUM 3
Special Functions
Selection of yarn type
Yarn Type Comment
Function
For different yarn types a
selection can be done
This selection will
enable/disable settings and
functionalities of the clearer
Impact
Core yarn: additional cut after
yarn break
Filament/Silk: no dynamic yarn
detector active
Slub yarn: better adjustment
based on the startsum of the
yarn base
63
USTER® QUANTUM 3
core spun yarn
Typical problems occurring
The most frequent faults with core spun yarn are:
• Missing core within a bobbin, this can be only some cm of
yarn up to hundreds of meters
• Missing core of the whole bobbin
• Core partially uncovered, affecting the fabric appearance
later on
• Core wound outside the yarn, affecting the fabric
appearance later on
• Core ends of splice or broken core looking outside the
yarn
• Different share of core depending on the draft
64
USTER® QUANTUM 3
core spun yarn
Typical problems occurring
• Depending on the end use core spun yarn can be found from
Ne 6 to Ne 80 (but also outside this range)
• Most cases it is an elastic core, but it can also be any type of
synthetic core or even metal core covered by the yarn
• The share of core is somewhere between 3% up to 15 or 20%
of share.
• The highest share of the core spun yarn produced I expect to
be in the range of 4% to 6%, depending on the end use
65
USTER® QUANTUM 3
Selection of yarn type
corespun yarn
66
USTER® QUANTUM 3
corespun yarn
How to adjust the CY channel
• The setting is not representing the percentage of core alone
• The variation of the yarn has to be taken into consideration
• The best way, if using core spun yarn is to close the setting
when normal yarn is running until it starts to cut.
• UQ3 CY-channel is a help and a good step in the right
direction, but it is limited.
• We have the chance to detect it directly after occurrence
• To be realistic we will have not much chance if share of core is
below 8%
• Therefore use CY alarm to 1/1km
67
USTER® QUANTUM 3
Selection of yarn type
Core spun yarn
CY UQC2 UQ 3
Cut at yarn break
(in order to cut the remaining core YES YES
in case of a break of the cover yarn,
by initiating an additional cut)
Detection of broken missing core
during running yarn by CY NO YES
(But the change of C signal must be
more than the normal variation of
the yarn)
Detection of missing cover during Broken cover
splice cycle by CY YES can be detected
by Jm setting.
68
USTER® QUANTUM 3
Special Functions
Ply-yarn setting
Plied Yarn Comment
Function
For plied-yarn the number of
threads can be defined
Impact
The single thread count will be
entered and the number of
threads, e.g. for a Ne 40/2 the
clearer will expect a signal
corresponding to Ne 20/1.
69
USTER® QUANTUM 3
Special Functions
Article according to the sensor type
Sensor Type Comment
Function
According to the clearer type,
an article can be specified for
capacitive or optical clearer
only
Impact
<C> only for capacitive
<O> only for optical
< - > for both sensor types
70
72 UQ 3 Service training SEA January 2015
