Uster Countum 3

USTER QUANTUM 3
Application Handbook
Yarn clearing on winding machines
Textile Technology / V1.0 / April 2011 / 316 050-10020
Contents
Table of contents
Status
Foreword
04.2011
Introduction
04.2011
Basics of yarn measurement and yarn clearing
04.2011
Disturbing thick- and thin places
04.2011
Count variations
04.2011
Splice clearing
04.2011
Periodic yarn faults
04.2011
Quality parameters of a yarn
04.2011
Foreign fibers
04.2011
Vegetable Matter Clearing
04.2011
10 Detection of polypropylene fibers with USTER QUANTUM 3
04.2011
11 Various settings and applications of USTER QUANTUM 3
04.2011
12 Clearing of special yarns
04.2011
13 The first hour at the new clearer system
04.2011
14 Frequently asked questions
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
Copyright 2010 by Uster Technologies AG. All rights reserved.

All and any information contained in this document is non-binding. The supplier reserves the right to modify the
products at any time. Any liability of the supplier for damages resulting from possible discrepancies between this
document and the characteristics of the products is explicitly excluded.
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
Purpose of the application handbook ....................................................................................... 1.1
1.2
Yarn faults and yarn clearer ....................................................................................................... 1.1
1.3
Short history of the USTER yarn clearers ............................................................................... 1.3
1.4
1.4.1
1.4.2
Origin of seldom-occurring yarn faults ..................................................................................... 1.5

Separation of frequent and seldom-occurring yarn faults .............................................................. 1.5
Distinction between frequent and seldom-occurring yarn faults .................................................... 1.6
1.5
Classification of seldom-occurring thick and thin places ....................................................... 1.7
1.6
Allocation of seldom-occurring yarn faults to the Classimat matrix...................................... 1.8
1.7
1.7.1
1.7.2
Structure of the USTER QUANTUM 3..................................................................................... 1.11
Features of USTER QUANTUM 3 and options .......................................................................... 1.12

Features versus measuring head types ...................................................................................... 1.13
Basics of yarn measurement and yarn clearing .................................................................. 2.1

2.1
Purpose of this chapter .............................................................................................................. 2.1
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
Monitoring of thick places .......................................................................................................... 2.1

The capacitive measuring principle ............................................................................................... 2.2
The optical measuring principle ..................................................................................................... 2.2
Yarn signal definitions .................................................................................................................... 2.3
Characteristics of the two measuring principles ............................................................................ 2.5
Environmental influences on yarn measurement and yarn clearing .............................................. 2.6
Selection of the suitable measuring principle ................................................................................ 2.7
2.3
2.3.1
Monitoring of foreign fibers in the yarn .................................................................................... 2.7

Characteristics of the sensor for foreign fibers .............................................................................. 2.8
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
Disturbing thick and thin places........................................................................................... 3.1

3.1
Introduction .................................................................................................................................. 3.1
3.2
Definition of the yarn body ......................................................................................................... 3.1
3.3
Interpretation of the yarn body .................................................................................................. 3.5
3.4
3.4.1
3.4.2
Disturbing thick places ............................................................................................................... 3.5

Classification matrix ....................................................................................................................... 3.5
Thick and thin places ..................................................................................................................... 3.7
3.5
3.5.1
3.5.2
Clearing limits for thick places .................................................................................................. 3.9

Standard way of optimizing clearing limits: Manual clearing limits entry ..................................... 3.10
Setting a smart clearing limit for disturbing thick places (NSL) ................................................... 3.11
3.6
3.6.1
Disturbing thin places ............................................................................................................... 3.14

Classification matrix ..................................................................................................................... 3.14
USTER QUANTUM 3
5.
Contents
3.7
3.7.1
3.7.2
Clearing limits for thin places .................................................................................................. 3.14

Setting a smart clearing limit for disturbing thin places (T) .......................................................... 3.17
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
Count variations .................................................................................................................... 4.1

4.1
Introduction .................................................................................................................................. 4.1
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
Count deviations.......................................................................................................................... 4.3

Determination of the mean value of a yarn .................................................................................... 4.3
Purpose of yarn count deviation monitoring................................................................................... 4.3
Monitoring of yarn count deviations during start-up in the C channel ......................................... 4.4
Monitoring of the yarn count while winding with the CC-channel ................................................... 4.5
4.4
4.4.1
4.4.2
C and CC settings ........................................................................................................................ 4.6

Yarn count deviations at start up (C) settings ................................................................................ 4.6
Setting a smart clearing limit for yarn count monitoring (CC) ........................................................ 4.8
4.5
4.5.1
4.5.2
4.5.3
4.5.4
4.5.5
Calculation of yarn count deviations ....................................................................................... 4.12

Determination of count deviations with the clearer installation .................................................... 4.12
Calculation of the count deviations of wrong bobbins (capacitive measurement) ....................... 4.13
Calculation of count variations of wrong bobbins optical measurement ................................... 4.15
Calculation of count variation of wrong bobbins with a diagram .................................................. 4.16
Relationship between the mass and diameter deviation with the USTER Calculator ................ 4.17
4.6
Example for the setting of the C-channel ................................................................................ 4.18
4.7
4.7.1
4.7.2
The effect of count deviations on the fabric appearance ...................................................... 4.19

Mixing two different yarn counts .................................................................................................. 4.19
Reasons and measures to minimize count variations ................................................................. 4.23
Splice Clearing ...................................................................................................................... 5.1

5.1
Introduction .................................................................................................................................. 5.1
5.2
Scatter plot of splices ................................................................................................................. 5.1
5.3
5.3.1
5.3.2
5.3.3
5.3.4
Splices .......................................................................................................................................... 5.3

Visual appearance ......................................................................................................................... 5.3
Practical example .......................................................................................................................... 5.4
Basic principles of splicing ............................................................................................................. 5.6
Wet Splicing ................................................................................................................................... 5.7
5.4
Splice classification of the USTER QUANTUM 3 .................................................................... 5.8
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
Upper yarn detection (U) ........................................................................................................... 5.13
5.7
Minimizing the number of splices ............................................................................................ 5.14
USTER QUANTUM 3
Contents
5.7.1
5.7.2
5.7.3
5.7.4
7.
Critical items which affect the number of splices ......................................................................... 5.14

Mean time between two splices ................................................................................................... 5.15
Field test ...................................................................................................................................... 5.16
Relationship between the productivity on winding machines and splices .................................... 5.17
Periodic yarn faults ............................................................................................................... 6.1

6.2
Influence of the yarn speed on the winding machine .............................................................. 6.2
6.3
Further reasons for periodic defects ......................................................................................... 6.2
6.4
6.4.1
Periodic fault registration with the PF ....................................................................................... 6.3

Setting for Periodic Faults (PF / Optional Q Data) ......................................................................... 6.3
6.5
6.5.1
The effect of periodic faults on the fabric appearance ............................................................ 6.6

Reasons and measures to minimize periodic mass variations ...................................................... 6.8
Quality parameters of a yarn................................................................................................. 7.1

7.1
Introduction .................................................................................................................................. 7.1
7.2
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
Yarn evenness ............................................................................................................................. 7.3

Definition of the coefficient of variation CV .................................................................................... 7.4
Reasons and effects of the yarn irregularity .................................................................................. 7.4
Deviation of the CV mean value of a group of clearers (CVMV) ................................................. 7.5
Deviation of the CV of a single winding position (CV-SP) ............................................................. 7.6
Settings .......................................................................................................................................... 7.7
Display of the CV values ................................................................................................................ 7.9
7.3
7.3.1
7.3.2
7.3.3
Imperfections ............................................................................................................................. 7.10

Definition of imperfections ........................................................................................................... 7.11
Settings ........................................................................................................................................ 7.13
Display of the imperfection results ............................................................................................... 7.15
7.4
7.4.1
7.4.2
7.4.3
7.4.4
Class-Alarm ................................................................................................................................ 7.15

Definition of the classes ............................................................................................................... 7.16
Reasons and effects of the faults ................................................................................................ 7.17
Settings ........................................................................................................................................ 7.17
Display of the class alarms .......................................................................................................... 7.18
7.5
7.5.1
7.5.2
Tailored classes (Option Advanced Classes) ......................................................................... 7.19

Settings ........................................................................................................................................ 7.20
Display of the tailored classes ..................................................................................................... 7.21
7.6
Adjustment of the individual alarm possibilities .................................................................... 7.22
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
Indication of ejected bobbins ................................................................................................... 7.33
7.9
Criteria to select the limits for quality characteristics ........................................................... 7.33
USTER QUANTUM 3
Contents
7.9.1
7.9.2
7.9.3
7.9.4
7.9.5
Installation of a quality management system to eliminate outliers ............................................... 7.34

Tracing back outlier bobbins to the source .................................................................................. 7.36
Examples from the industry ......................................................................................................... 7.38
Recommendations for a sampling plan ....................................................................................... 7.39
Conclusion ................................................................................................................................... 7.41
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
Foreign fibers ........................................................................................................................ 8.1

8.1
Introduction .................................................................................................................................. 8.1
8.2
Dense Area ................................................................................................................................... 8.3
8.3
8.3.1
8.3.2
8.3.3
8.3.4
8.3.5
Foreign fibers ............................................................................................................................... 8.5

Types of foreign material in cotton................................................................................................. 8.5
Degree of contamination of bales .................................................................................................. 8.8
Size and appearance of foreign matter in spinning mills ............................................................. 8.10
Frequency of foreign fibers in spinning mills ................................................................................ 8.11
Foreign fiber risk calculated for a spinning mill ............................................................................ 8.12
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
Clearing limits ............................................................................................................................ 8.13

General references for foreign fiber clearing ............................................................................... 8.14
Clearing limits for dark foreign fibers in light yarn ........................................................................ 8.14
Setting a smart clearing limit for dark foreign matter (FD) ........................................................... 8.17
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
Vegetable Matter Clearing .................................................................................................... 9.1

9.1
9.1.1
9.1.2
Introduction .................................................................................................................................. 9.1

Vegetable matter ........................................................................................................................... 9.2
Distribution of vegetables and foreign fibers .................................................................................. 9.3
9.2
Dense area for vegetable matter (VEG) ..................................................................................... 9.3
9.3
Classification matrix of vegetable matters with the USTER QUANTUM 3 ........................... 9.6
9.4
9.4.1
Clearing limits .............................................................................................................................. 9.6

Setting a clearing limit for vegetable matter (VEG)........................................................................ 9.7
9.5
Vegetable matters and their effect on the fabric appearance ................................................. 9.9
USTER QUANTUM 3
Contents
9.5.1
9.5.2
10
Field test ........................................................................................................................................ 9.9

Reasons and measures to minimize vegetable matter in yarns .................................................. 9.11
Detection of polypropylene fibers with USTER QUANTUM 3 ......................................... 10.1
10.1
10.1.1
10.1.2
10.1.3
Introduction ................................................................................................................................ 10.1

Configuration of a PP-clearer ...................................................................................................... 10.3
Frequency of PP fibers ................................................................................................................ 10.4
Application range of PP-clearing, ring-spun yarn ........................................................................ 10.6
10.2
Scatter plot ................................................................................................................................. 10.7
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
Various settings and applications of USTER QUANTUM 3 .............................................. 11.1
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
Display of Data and Alarms ...................................................................................................... 11.3

Display of Data and Alarms with the help of bar graphs .............................................................. 11.3
Display of Data and Alarms with the help of exception reports ................................................... 11.5
Display of yarn faults with the help of textile alarms .................................................................... 11.6
11.3
11.3.1
11.3.2
11.3.3
Collecting defects ........................................................................................................................ 11.8

Introduction .................................................................................................................................. 11.8
Event display by the red light at the sensor (iMH-LED) ............................................................... 11.8
Yarn fault cards............................................................................................................................ 11.9
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 winding functions............................................................................................ 11.11
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
Clearing of special yarns .................................................................................................... 12.1

12.1
Introduction to fancy yarns ...................................................................................................... 12.1
12.2
Clearing of fancy yarns ............................................................................................................. 12.1
12.3
Clearing of slub yarns ............................................................................................................... 12.3
12.4
Clearing of yarns with nep or loop effects .............................................................................. 12.5
12.5
Melange yarns ............................................................................................................................ 12.6
12.6
Core yarn .................................................................................................................................... 12.7
USTER QUANTUM 3
0
13
14
Contents
The first hour at the new clearer system ........................................................................... 13.1

13.1
Introduction ................................................................................................................................ 13.1
13.2
Short description of the settings ............................................................................................. 13.1
Frequently asked questions ............................................................................................... 14.1

14.1
14.1.1
14.1.2
14.1.3
14.1.4
14.1.5
Product related questions ........................................................................................................ 14.1
What type of sensing principles does USTER QUANTUM 3 offer?........................................... 14.1
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
Application related questions .................................................................................................. 14.6

What kind of yarn clearer do I need for my application? ............................................................. 14.6
How is it possible to simplify the definition of clearing limits? ...................................................... 14.6
How can one find the optimal setting for basic clearing? Is it the same as before? .................... 14.7
What is the best basic setting for my yarn? ................................................................................. 14.7
How can one find the optimum setting for good fabric appearance and for optimum
productivity? ................................................................................................................................. 14.7
14.2.6 Which setting shall I use to make sure that no Classimat objectionable faults will remain? ....... 14.7
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
Technical specifications ..................................................................................................... 15.1

15.1
15.1.1
15.1.2
15.1.3
15.1.4
Basics of USTER QUANTUM 3 ............................................................................................... 15.1

Architecture.................................................................................................................................. 15.1
Scope of application .................................................................................................................... 15.1
Scope of supply ........................................................................................................................... 15.1
Miscellaneous .............................................................................................................................. 15.2
15.2
Structure of the USTER QUANTUM 3..................................................................................... 15.2
15.2.1 Features of USTER QUANTUM 3 and options .......................................................................... 15.2

15.2.2 Features versus measuring head types ...................................................................................... 15.3
15.3
Comparison, capacitive versus optical measuring principle for basic clearing ................. 15.4
15.4
Winding machines ..................................................................................................................... 15.5
15.5
Count range of the USTER QUANTUM 3 ............................................................................... 15.5
15.6
Architecture, sensor principles and configuration ................................................................ 15.6
15.7
Elimination of disturbing yarn faults ....................................................................................... 15.7
15.8
Supervision of the machine operations .................................................................................. 15.8
15.9
Determination of quality characteristics ................................................................................. 15.9
15.10
Cut alarms, Quality alarms, Special Counters and Logbook .............................................. 15.11
15.11
Reports ..................................................................................................................................... 15.13
15.12
Clearing of various yarn types ............................................................................................... 15.15
15.13 Recommendations how to use clearers ................................................................................ 15.16

15.13.1 Sensor systems versus end use of yarn .................................................................................... 15.16
15.13.2 Poor environmental conditions .................................................................................................. 15.18
16
Appendix .............................................................................................................................. 16.1

16.1
Standard settings ...................................................................................................................... 16.1
16.1.1 Standard settings for the capacitive clearer Capacitive Default ............................................... 16.1
16.1.2 Standard settings for the optical clearer Optical Default .......................................................... 16.2
16.2
Abbreviations ............................................................................................................................. 16.3
16.3
Explanation of terms ................................................................................................................. 16.7
16.4
16.4.1
16.4.2
16.4.3
16.4.4
International Systems of units ............................................................................................... 16.11

International system ................................................................................................................... 16.11
'SI' system .................................................................................................................................. 16.11
Conversion table for yarn count systems................................................................................... 16.13
Conversion of English units into metric units ............................................................................. 16.14
16.5
Bibliography ............................................................................................................................. 16.15
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
Purpose of the application handbook
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:
Introduction to yarn clearing
for beginners and students
Instructions for optimum use
for the quality management of a spinning mill
Basis for the application training
for the instructor
In order to understand the explanations in this application handbook, it is advantageous, if:
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
Validity of this Application Handbook

The explanations in this Application Handbook refer to the functions of the USTER QUANTUM 3.
They are subject to change without notice.
Abbreviations and explanation of terms
In the appendix of this book (section 16.2 and 16.3) a list of all the abbreviations and explanations of
terms is given.
1.2
Yarn faults and yarn clearer
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.
Prevent the origin of yarn faults by adequate measures.
2.
Remove yarn faults by the aid of yarn clearers.
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
Principle of yarn clearing on the winding machine
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
Short history of the USTER yarn clearers
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:
Monitoring and elimination of disturbing yarn faults
Monitoring and controlling of machine functions
Determination of quality parameters of the yarn
Triggering of alarms if outlier bobbins occur
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
Origin of seldom-occurring yarn faults
1.4.1 Separation of frequent and seldom-occurring yarn faults

During the spinning process, a card sliver with about 20'000 to 40'000 fibers in the cross-section is
drawn to a yarn with about 40 to 1000 fibers in the cross-section. 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. Only spinning mills with a permanent improvement process are able to keep these random variations within close limits.
These variations are measured by the evenness tester in the laboratory. They are a measure for the
unevenness of the yarn and are called imperfections. They occur so frequently that they are not eliminated from the yarn (Fig. 1-4). Their number of imperfections is generally given per 1000 m of yarn.
In contrast to the frequent yarn faults, there are also the seldom-occurring yarn faults. The difference
between the frequent yarn faults and the seldom-occurring yarn faults is mainly given by the larger
mass or diameter deviation. As these faults occur only seldom, their number is expressed per 100'000
m. These faults are monitored and classified by the USTER CLASSIMAT or by the clearer installation on the machine.
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
Classification matrix for disturbing thick and thin places
1.4.2 Distinction between frequent and seldom-occurring yarn faults

Fig. 1-6 shows the position of the frequent yarn faults (imperfections, green area in Fig. 1-6) in comparison to the position of the seldom-occurring yarn faults in the classification matrix. It is obvious,
that both types of yarn faults differ from each other clearly by their.
In addition, the areas of the clearer settings N, S, L, T, CCp and CCm are indicated. This shows
where the settings are effective. N = neps, S = short thick places, L = long thick places, T = thin places, CCp = count deviations in positive direction, CCm = count deviation in minus direction.
Fig. 1-6
1.6
Positions of the frequent versus the seldom-occurring yarn faults
USTER QUANTUM 3
Introduction
1.5
Classification of seldom-occurring thick and thin places
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:
The cross-section of the fault compared to the mean value
The length of the fault
The count of the yarn
The yarn density in the fabric
The type of fabric (weaving or knitting)
USTER QUANTUM 3
1.7
Introduction
1.6
Allocation of seldom-occurring yarn faults to the Classimat matrix
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
Possible reason of faults
A (Thick place)
Comments
A0
Extended class, mainly used for ply yarn and compact yarn
A1
Bad condition of carding, blow room, trash in yarn
A2
Bad condition of carding, blow room, trash in yarn
A3
Neps, fluff, foreign matters, dirty drafting zone
A4
Ring front zone dirty, fly in trumpet
B0
B1
Fibers damage in process, spindle without aprons
B2
Fibers damage in process, spindle without aprons
B3
Fluff in travelers, unsuitable travelers, bad piecing
B4
Slub from ring spinning department
C0
C1
Bad piecing in cans, sliver entanglements
C2
Bad piecing in cans, sliver entanglements
C3
Piecing, ring spinning
(Unacceptable faults)
C4
Floating fibers, fly, slub
D0
D1
Floating fibers
D2
Gauge problem of roving frame, spacer problem
D3
Fluff in ring spinning or roving
D4
Fluff in ring spinning or roving
E (Thick place)
Double yarn, count variation
(Spinners double)
F (Thick place)
Bad piecing in ring yarns, roving & back process
(Long thick places)
G (Thick place)
Bad piecing in ring, roving & back process etc.
(Long thick places)
H (Thin place)
H1
Mostly eccentric bobbins on roving & ring frames, eccentric

spindles, drawing problems
(Thin places)
H2
Poor handling of material during processes
(Thin places)
I1
This type of faults is mostly produced by separation of

parts of sliver or roving prior to spinning
(Long thin places)
I2
This type of faults is mostly produced by separation of

parts of sliver or roving prior to spinning
(Long thin places)
B (Thick place)
C (Thick place)
D (Thick place)
I (Thin place)
Table 1
1.8
(Short thick places)
Classimat defects / Classification and sources of origin. New classes are not mentioned in Table 1.
USTER QUANTUM 3
Introduction
Disturbing yarn faults caused by raw material and card

These faults depend on the quality of the raw material. For natural fibers, they depend mainly on the
physical properties such as fiber fineness, length and short fiber content. For synthetic fibers, the
faults depend mainly on the disentanglement of single fibers. Insufficient disentanglement can lead to
felted single fibers, which might be caused by softeners, oil additives, lubricants or climatic conditions.
Disturbing yarn faults caused by processes prior to spinning
These faults are characterized by extreme diameter variations or poor friction of the fibers. Often, it is
a matter of fiber packages, which are not caught in the draw-box of prior processes and were not
drawn apart. Therefore, they show a big increase of the mass or diameter in the yarn.
Disturbing yarn faults caused in spinning

Most disturbing yarn faults are caused by spun-in fly in the area of the ring spinning machine and by
fiber residues, which cling to the draw-box or other parts of the spinning machine and which are swept
away from time to time and are spun into the yarn.
Furthermore, it is possible that different setting possibilities of the ring spinning machine, as e.g. draft
or distance settings of the draw-box, have an influence on the number of seldom-occurring yarn
faults.
Thick places in a woven fabric are shown in Fig. 1-8 to Fig. 1-9. Here we can see a spun-in fly failure.
This refers to free fibers which fall into the drafting elements or onto the roving which is being fed into
the drawing unit of the ring spinning machine and are then twisted into the yarn along their entire
length.
Fig. 1-8
Flying fibers which fall onto the roving or

into the drafting elements and are then
twisted into the yarn
USTER QUANTUM 3
Fig. 1-9
Thick place in woven fabric as a result of

a spun-in fly
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
Classification matrix for foreign fibers and vegetables
Foreign fiber in a yarn
Fig. 1-12
Vegetable in a yarn
USTER QUANTUM 3
Introduction
1.7
Structure of the USTER QUANTUM 3
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
New features of USTER QUANTUM 3
USTER QUANTUM 3
1.11
Introduction
1.7.1 Features of USTER QUANTUM 3 and options

Table 1-2 shows the individual features of the options.
OPTIONS
Basic clearing
Foreign
matter
FEATURES
COMMENTS
Yarn Body (N, S, L, T, CC)
Visualization of the yarn characteristics
Smart limits (N, S, L, T, CC)
A proposed starting point for clearing limits
Scatter plot (N, S, L, T, C, CC, J)
Visualization of the thick and thin places, count deviations

and splices.
N, S, L, T
Elimination of the disturbing thick and thin places
C, CC
Count deviation clearing and monitoring
Jp, Jm
Splice Clearing
Cut forecast
A forecast of cut numbers per 100 km
Technical alarms
Alert for technical problems
Textile alarms
Alert for textile problems
Dense Area (FD, VEG)
Identification of range where foreign fibers are located
Smart limit (FD)
A proposed starting point for foreign fiber clearing limits
Vegetable
Clearing
Scatter plot (FD)
Visualization of dark foreign fibers
(Option)
Dark foreign matter (FD)
Elimination of dark foreign fibers
On-line foreign matter classification
Classification of foreign fibers
Identification of vegetables
Separation of vegetable matter
On-line vegetable classification
Classification of vegetable matter
Polypropylene fibers
(Option)
Smart limit (PP)
A proposed starting point for polypropylene clearing limit
Scatter plot (PP)
Visualization of polypropylene fibers
Q-Data (Option)
Evenness (CV)
Determination of the yarn evenness
Imperfections
Determination of the frequent thick places, thin places and

neps
Basic on-line classification (NSLT, FD, J and

VEG)
Classification of disturbing thick and thin places, foreign

fibers, splices and vegetables
Class alarms
Triggering of alarm if the number of disturbing faults has

exceed the selected number of faults
Periodic Faults (PF)
Detection of periodic faults
Absolute hairiness measurement
Determination of the hairiness value
Exception spindle detection
Recognition of spindles with excessive hairiness
Expert
Access to the data output for Expert System and centralized data collection and reporting
Extended Classes
Classification of additional classes in NSLT, F, VEG
Tailored classes
Classes can be selected by customers
Software pack
Software pack consists of Hairiness, Advanced Classification and Expert
Hairiness
(Option)
Expert (Option)
Advanced
Classification (Option)
Lab On-line
(Option)
Table 1-2
1.12
Features of Basic Clearing and options
USTER QUANTUM 3
Introduction
1.7.2 Features versus measuring head types

Table 1-3 below describes what type of USTER QUANTUM 3 sensor for each measuring head is
appropriate for which kind of application.
USTER QUANTUM 3 SENSORS
FEATURES
MEASURING HEAD TYPES
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
ADVANCED CLASSIFICATION (Option)
LAB ONLINE (Option)
---
---
---
Table 1-3
The USTER QUANTUM 3 sensors and options
Key:
X
This feature is included in this version of the sensor
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
---
Not available with this iMH type
USTER QUANTUM 3
1.13
1.14
Introduction
USTER QUANTUM 3
Basics of yarn measurements and yarn clearing
Basics of yarn measurement and yarn clearing
2.1
Purpose of this chapter
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
Monitoring of thick places
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
Electrical yarn signal

+V
0
-V
Fig. 2-1
Yarn signal, result of a thick place
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
The capacitive measuring principle

4
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
The optical measuring principle

4
2
1
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
Yarn signal definitions
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
Definition of the yarn signal
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
Yarn signal (capacitive)
Yarn signal (optical)
0% base value
0% base value
Increase of cross-section: +100% Increase of diameter: +41%
Decrease of cross-section: -50%
Decrease of diameter: -29%
Relationship between the cross-section and diameter
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
Optical and capacitive measuring systems
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
Characteristics of the two measuring principles
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
Corresponds to the mass/crosssection of the yarn or the number of

fibers in the measuring field
Corresponds to the diameter of

the yarn
Measuring field length
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
Evaluation of the yarn fault

Normal yarn fault
The fault is evaluated with the full

increase of the cross-section in percent.

increase of the diameter in percent.
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.
Short yarn faults, length: 3 mm

increase of mass.

increase of the diameter.
Very compact yarn fault

increase of the cross-section. Due to
the higher number of fibers in the
cross-section, the thick place can
absorb more dye stuff and appears
darker in the end product.
This compact yarn fault absorbs

only a small amount of light. The
increase of the diameter is considered as too insignificant in
comparison to the cross-section.
The distance between two white

lines is 1 cm.
Table 2-2
Properties of the measuring principles
USTER QUANTUM 3
2.5
2.2.5
Environmental influences on yarn measurement and yarn clearing
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
Capacitive measuring principle
Optical measuring principle
Fiber material
Most fiber materials can be measured with both measuring principles.

Yarns, which contain electrically conductive Can be measured without limitations.
fibers or are treated with electrically conductive spinning additives, cannot be measured.
Colored yarns
No or only little influence
Color differences within the bobbins can

lead to different sensitivities (see 2.4.2,
Calibration process on a running yarn), but
can also serve for the monitoring of color
differences.
Dark yarns require in most cases other
settings than light yarns.
Fiber blends
No or only little influence

Wrong fiber blends can be monitored within
certain fiber differences with the C- and CCchannel (see chapter "Count variations").
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
change of the yarn signal caused by the contamination is compensated within

certain limits. If the contamination gets too high, a technical alarm is triggered.
Atmospheric
humidity
Normal variations in the humidity have no influence.
Yarn moisture
Normal variations have no influence as long as the yarn structure doesnt change.
Non-homogenous yarn humidity can lead to
unjustified cuts.
Very dry yarns exhibit a higher hairiness.

This suggests a larger diameter and can
lead to unjustified cuts.
If wet splicing is used, Uster Technologies

must be consulted.
Table 2-3
2.6
Environmental influences and their effects
USTER QUANTUM 3
Moisture of the yarn / Capacitive measuring system

One characteristic of textile material is the ability to absorb moisture. The moisture that can be absorbed depends on the relative humidity of the environment.
Cotton contains about:
6,6 percent by weight of moisture at a relative humidity of 50%
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
Selection of the suitable measuring principle
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
Monitoring of foreign fibers in the yarn
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
Characteristics of the sensor for foreign fibers
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
Evaluation of foreign fibers
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
Communication of the yarn clearer with the winding machine
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
Zero point adjustment
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
Calibration process on a running yarn
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
Deviations to the nominal value
Storing of the calibration values for the optical sensor

When processing colored yarns with the optical sensor, color sensitivity differences between the sensors can lead to start-up problems and to changes in the clearing sensitivity. In order to avoid this
problem, it can be switched to "O-Single Adj" by means of the article.
This has the effect that the calibration value is calculated for each sensor individually and not per
group.
Calibration procedure for foreign fiber clearing
Each sensor calculates its own individual foreign fiber calibration. The fine adjustment of the calibration value is also carried out for each single sensor. The principle procedure is the same as for thick
places.
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 off
Yarn in the measuring field
SYD = turned on
If the SYD is turned off, the DYD cannot be turned on.
Yarn mean value
0%
threshold
No yarn
-100%
on
SYD
Static yarn detector
off
Fig. 2-8
Status of the static yarn detector SYD
The SYD is switched on as soon as the threshold is reached.
Dynamic yarn detector DYD

The dynamic yarn detector DYD determines if the yarn in the measuring field is running or not.
Yarn in the measuring field is stopped
Yarn in the measuring field runs
DYD = off
DYD = on
If the DYD is turned off, the clearing channels are blocked.
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
Yarn detector test function

The status of the static and dynamic yarn detector can be displayed at the iMH-LED (iMH = intelligent
measuring head / LED = light emitting diode), Fig. 2-9:
service / special functions / iMH LED display. SYD/DYD, press OK.
No yarn: off
SYD:
DYD:
Fig. 2-9
Setting of the iMH-LED display function
Fig. 2-10
Display of the status of the yarn detector at the iMH-LED
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
Winding machine / Drum drive with drum impulse sensor
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
Disturbing thick and thin places
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
Definition of the yarn body
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).
The yarn body is composed of two parts:
Dark green area representing the real yarn body.
Light green area representing yarn body variations.
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.
Area of the disturbing faults
Area of the yarn body
Area of the disturbing faults
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
Development of the yarn body / Example of Ne 30/1, 100% cotton yarn

The clearing system calculates the yarn body already after a few seconds. The yarn body will be more
accurate after some additional kilometers.
Fig. 3-2
Yarn body after 4,6 km
Fig. 3-3 Yarn body after 49,2 km
Fig. 3-4 Yarn body after 72,6 km
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
Examples of various yarn bodies
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
Interpretation of the yarn body
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
Disturbing thick places
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)
S faults: thick places from 1 cm to < 8 cm
short thick places (L fault)
L faults: thick places as of 8 cm
long thick places
USTER QUANTUM 3
3.5
Fig. 3-9
Classification system for the settings N, S and L
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
Classification matrix for NSL
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
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
Mean value (0%)

Negative
threshold
- 100%
2 mm pieces
Fig. 3-11
Yarn signal with threshold
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
In Fig. 3-13, the signal of the first fault is enlarged.
Fig. 3-13
Enlarged yarn fault, first significant thick place, 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
Yarn faults with 260 300% and a length of 16 mm
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
Clearing limits for thick places
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
Clearing limit of N, S and L by means of max 8 set points
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
Standard way of optimizing clearing limits: Manual clearing limits entry
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
Clearing limits on the screen of the control unit
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
Setting a smart clearing limit for disturbing thick places (NSL)
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
The yarn body.
Scatter plot of the cut faults and

remaining events.
Number of expected fault cuts /

100 km.
Clearing limit
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. 3-18
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
The setting of USTER QUANTUM 3 can be done simply in one step:
Fig. 3-19
Start with standard setting
Fig. 3-20
Only one step / Press Smart Limit button

and get a proposed setting including the
cut forecast based on the yarn running
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
=
Smart Limit 1 step less

sensitive.
Smart Limit 1 step more

sensitive.
= Show yarn body,
scatter plot and recalculate the expected cuts / 100 km.
confirm and activate

optimized clearing
limit.
= Cancel all modifications

Fig. 3-21
3.12
Proposed setting is a starting point for optimization
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 online classification
NSLT yarn faults are displayed together with all other yarn faults of the machine, a group or a winding
position.
Fig. 3-23
NSLT yarn fault registration
USTER QUANTUM 3
3.13
3.6
Disturbing thin places
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
Area of thin places in the classification matrix (red square)
Clearing limits for thin places
The evaluation of a thin place is similar to NSL
Fig. 3-25
3.14
Clearing limit for the T-channel
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.
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
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
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
Setting a smart clearing limit for disturbing thin places (T)
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.
Green dots = remaining
events.
=Yarn body
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
Start with standard setting
USTER QUANTUM 3
Fig. 3-30
Only one step / Press smart limit button

and get a proposed setting including the
cut forecast based on the yarn running
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.
= The new setting point proposals

= Smart Limit 1 step less sensitive.
= Smart Limit 1 step more sensitive.
= Show yarn body, scatter
plot and recalculate the
expected cuts / 100 km.
= confirm and activate optimized
clearing limit.
= Cancel all modifications
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
NSL T online classification
USTER QUANTUM 3
3.8
The effect of thick and thin places on the fabric appearance
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
S4 Faults caused by static

charges or damaged aprons
S5 Collections of fly waste
pushed together at the ring traveller
Fig. 3-33
Formation of faults on the ring spinning machine

S1 Spun in fly
This refers to free fibers which
fall into the drafting elements or
onto the roving being fed into the
drawing unit. These fibers are
then twisted into the yarn along
their entire length
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.
S3 Long collections of fly

These are fibers which stick
together on aprons or rollers and
from time to time are collected
and carried along by the yarn.
S4 Fish (corkscrew-type faults)

Faults caused by static charging
or damaged aprons
These faults occur due to static
charging or are a result of unsuitable drafting aprons or drafting aprons which have cracked
surfaces.
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.
S6 Chains of faults S1, S2, and

S3
These are combinations of the
faults S1, S2, and possibly also
S3 which occur in short succession, one after the other, along
the length of the yarn.
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.
Table 3-1 Spinning faults
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
Flying fibers which fall onto the roving or

into the drafting elements and are then
twisted into the yarn
Fig. 3-35
Thick place in woven fabric, type S4

(see Fig. 3-33, Table 3-1)
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
Thick place in a T-shirt / 100% polyester
Fig. 3-37
Thick place in a T-shirt
Fig. 3-38
Thick place in a T-shirt, magnified
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
Thick place in jeans / 100% cotton, Nec

18 (33 tex), OE rotor yarn
Fig. 3-40
Thick place in jeans, zoomed
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
Thick place, ladies pants / 100% cotton, OE rotor yarn
Fig. 3-42
Thick place, ladies pants
USTER QUANTUM 3
Fig. 3-43
Thick place, ladies pants, zoomed
3.23
3.8.2
Reasons and measures to minimize seldom-occurring thick places
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
Possible Reasons and Preventive Actions

Improper function of the autolevelling at finisher drawframe can
cause long thin and thick places in the slivers which will results
in long thin and thick places in the yarns or even in wrong yarn
count
High short fiber content in sliver or roving
Optimize comber settings (comber noil) in order to achieve the
maximum short fiber removal
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
Ring spinning frame
Contamination too high / Cleaning of ring spinning machine

regularly
Improper distance settings of a traveler cleaner at the ring
spinning machine
Air condition system performance in spinning not under control
Avoid high amount of end breaks because it will result in a high
number of outlier bobbins and excessive fly formation
Optimize previous process stages to avoid or minimize slubs
Avoid poor yarn joints
Avoid eccentric front rollers in roving and spinning
Avoid fiber accumulations on rollers and aprons
Avoid false draft in ring spinning machine creel or improper
spinning draft distributions
Aprons worn out or damaged
Rings and ring travelers worn out
Wrong settings of the travelling overhead cleaner
Improper apron settings
Incorrect choice of the traveler profile and weight
Lint accumulation by rollers
Winding machine
Winding speed too high
Table 3-2 Preventive measures and tools for the management of seldom-occurring events / thick places
3.24
USTER QUANTUM 3
SELDOM-OCCURRING EVENTS / Thick Places / USTER Tools for Improvement

Tools
Improvement
Constant sliver quality and yarn quality
Adjustment of autolevellers
Proper settings of the clearing limits
USTER Testing off-line

USTER Testing on-line
USTER QUANTUM CLEARER
Monitor long-term quality level to secure consistency

Separate outlier bobbins with quality data
USTER EXPERT SYSTEMS
Monitor long-term variation of cut ratio and yarn quality
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
Hole in a knitted fabric after five

washing cycles
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
Thin places in knitted T-shirt / 100% cotton, combed
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
Thin places in cotton T-shirt / 100% cotton,

carded, Ne 26 (22,5 tex)
Fig. 3-48
Thin places in cotton T-shirt,

magnified
USTER QUANTUM 3
3.8.4
Reasons and measures to minimize seldom-occurring thin places
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
Improper function of autolevelling at finisher drawframe can

cause long thin and thick places in the slivers which will results in long thin and thick places in the yarns or even in
wrong yarn count
Roving frame
High unevenness of roving

Tension problems in roving
Weak roving
Eccentric front rollers
Aprons worn out
Ring spinning frame
False draft in ring spinning machine creel

Eccentric front rollers
Aprons worn out
Blocked trumpets
Blocked drafting cages
Missing instruction and training of operators
Apron worn out or damaged
Winding
High winding speed and winding tension
Table 3-4 Preventive measures and tools for the management of seldom-occurring events / thin places
SELDOM-OCCURRING EVENTS / Thin Places / USTER Tools for Improvement

Tools
Improvement
Systematic quality control of sliver quality with the USTER

TESTER
Adjustment of autolevellers
Proper setting of the clearing limits

Separate outlier bobbins with quality data software of the

clearer
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:
Deviations by mixing in wrong bobbins
Peeled-off or uneven rovings can lead to significant count deviations within a bobbin
Missing sliver from a finisher drawframe without an autolevelling system
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
Definition of the yarn body for long-term variations (C and CC faults)
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:
Dark green area representing the real yarn body
Light green area representing yarn body variations
USTER QUANTUM 3
4.1
Count variations
The yarn body for C is composed of two parts (Fig. 4-1):
Dark green line representing the real yarn body.
Light green line representing yarn body variations.
Fig. 4-1
Yarn body display for C, defined from 2 to 12 m
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
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
Determination of the mean value of a yarn
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
Purpose of yarn count deviation monitoring
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
Clearing limits N, S, L, T, C+, C-, CCp and CCm
USTER QUANTUM 3
4.3
Count variations
4.3.3
Monitoring of yarn count deviations during start-up in the C channel
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:
Cp sensitivity setting for the detection of yarn diameter or mass increases
Cm sensitivity setting for the detection of yarn diameter or mass decreases
Reference length
The choice of the thresholds depends on different factors and must be adjusted to the conditions of
the mill:
the produced yarn counts of the spinning mill
the evenness of the yarn
the possibilities of the winding machine to determine the suction length
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
Monitoring of the yarn count while winding with the CC-channel
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
Yarn suction after a CC-cut / Machines with fault-related yarn suction

Modern winding machines provide a measurable, fault related yarn suction. The winding position gets
the information from the yarn clearer, how much yarn has to be sucked-off before the splice is carried
out.
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
Display of C setting, only one reference

length to be set
Fig. 4-6
Display of CC setting. Smart limits available for length classes from 2 12 meters.
Yarn count deviations at start up (C) 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.
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
The yarn body.

Clearing limit
A rea of actual yarn count.
Red dots = cut yarn faults
Fig. 4-7
Display of C setting, only one reference length to be set
Scatter plot of yarn count monitoring at start-up / Practical example
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
Yarn Ne 24, cotton 100%, carded,

capacitive sensor, 10035.2 km.
Open settings, reference length is 10 m.
Fig. 4-10 Yarn Ne 24, cotton 100%, carded, capacitive sensor, 3067.9 km.
Close settings, reference length is 10 m.
Setting a smart clearing limit for yarn count monitoring (CC)
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:
2 Set points: CCp +% at 2 m and 12 m
2 Set points CCm -% at 2 m and 12 m.
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
=Yarn body
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
Start with standard setting. Press Smart

Limit key
Fig. 4-13 Only one step / Display of CC setting, smart

limits available for length classes from 2
12 meter
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.
=
= 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
C and CC fault reports
USTER QUANTUM 3
Count variations
Scatter plot of medium-term deviations / Practical example
Fig. 4-16
Fig. 4-17
Frequent medium-term deviation of the count. Analysis of the spinning process required.
Yarn Ne 40, cotton 100%, carded, knitFig. 4-18

ting, capacitive sensor, 1582 km.
Low number of count deviations within the
range of 2 to 12 m, 0,8 + 0,2 = 1,0 per
100 km.
USTER QUANTUM 3
Yarn Ne 32, cotton 100%, carded, knitting,

capacitive sensor, 3496 km, wider yarn
body, same clearing curve as seen on the
left hand side.
High number of count deviations between 2
and 12 m, 3,4 + 1,5 = 4,9 per 100 km.
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.
Calculation of yarn count deviations
The determination of the setting parameters for the yarn count deviation monitoring must be carried
out very carefully. Different aids are at disposal.
Determination of count variations with the clearer installation
Calculation of the count variations with formulas
Determination of count variations with a diagram
Determination of count variations with the USTER Calculator
4.5.1
Determination of count deviations with the clearer installation
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
Wrong yarn B( ADMV) yarn A( ADMV)

100%
yarn A( ADMV)
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
Example 1: Article A is mixed up with a coarser yarn, article B (capacitive measurement)
Article A:
Ne 30
ADMV: 776
Article B:
Ne 20
ADMV: 1204,2

1204,2 776,0
100 = 55,2%
100% =
776,0
yarn A( ADMV)
This means, that the difference between Ne 30 and Ne 20, measured with the capacitive sensor, results in a mass increase of 54,6%.
Example 2: Article A is mixed up with a coarser yarn, article B (optical measurement)
Article A:
Ne 30
ADMV: 4578,4
Article B:
Ne 20
ADMV: 5513,6
Diameter deviation( %) =

5513,6 4578,4
100% =
100 = 20,4%
yarn A( ADMV)
4578,4
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
Calculation of the count deviations of wrong bobbins (capacitive measurement)
Count deviations between yarns of the same fiber material

For the iMH-C count deviations can be determined according to formula 1 below:
Formula 2:
Wrong yarn B( tex) yarn A( tex)

100%
yarn A( tex)
Example 1: Article (yarn A) is mixed up with a finer yarn

Yarn A (33,3 tex) is mixed up with yarn B (25 tex)
( B A)
8,33
( 25 33,3)
100% =
100% =
= 25%
A
33,3
33,3
USTER QUANTUM 3
4.13
Count variations
Example 2: Article (yarn A) is mixed up with a coarser yarn

Yarn A (25 tex) is mixed up with yarn B (33,3 tex)
( B A)
( 33,3 25)
8,33
100% =
100% =
= +33%
A
25
25
Count deviations between yarns of different fiber material

If count deviations between yarns of different fiber material in blended yarns should be monitored, the
deviations can be calculated with formula 2 below. The different material factors have to be taken into
account.
Formula 3:
value of yarn B ( yarn A factor)

100 %
A factor
Yarn material
Factors
Relative humidity
0,86
80%
0,77
65%
0,69
50%
Acetate, Acrylic, Polyamide
0,62
65%
Polypropylen, Polyethylene
0,56
65%
Polyester
0,50
65%
Polyvinylchloride
0,45
65%
Cotton, wool, viscose
Table 4-1
Factors of the yarn material
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
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:
20 tex: 20 x factor 0,77 = 15,4

19,2 tex: (B x factor PE x %-share) + (B x factor CO x %-share) =
(19,2 x 0,5 x 0,67) + (19,2 x 0,77 x 0,33) = 11,3
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
Calculation of count variations of wrong bobbins optical measurement
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).
Determination of the mass deviation according to the following examples 1 and 2.
Conversion of the mass deviation to diameter deviations with the help of the USTER Calculator.
Example 1: Article A (33,3 tex) is mixed up with bobbins B (25 tex)

BA
8,33
100% =
100% = 25%
A
33,3
-25% mass deviation -13% diameter deviation

Example 2: Article A (25 tex) is mixed up with bobbins B (33,3 tex)
BA
+8,33
100% =
100% = + 33%
A
25
+33% mass deviation +16% diameter deviation

It has to be taken into account that with the optical monitoring of wrong bobbins, the diameter deviations are percentage-wise smaller than mass deviations.
In order to compensate the variation of the yarn count, the channels C and CC should also be set
about 5% more sensitive than the calculated values.
USTER QUANTUM 3
4.15
Count variations
4.5.4
Calculation of count variation of wrong bobbins with a diagram
The following diagram can only be used for the calculation of count variations when the capacitive
measuring head is used.
%
-50 -45 -40 -35 -30 -25 -20 -15 -10
-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
Conversion of mass and diameter deviations with the USTER Calculator

(6 = diameter scale, 7 = mass scale)
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
Setting of the USTER Calculator (1)
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
Settings of the USTER Calculator (2)
Example for the setting of the C-channel
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
The effect of count deviations on the fabric appearance
4.7.1
Mixing two different yarn counts
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
Yarn quality results
USP07 = USTER STATISTICS 2007

2D
= Optically measured diameter with the USTER TESTER 5 / Measurement of the yarn diameter with 2 light beams of 90 degrees
= Density measured with the USTER TESTER 5
Fig. 4-25
4.20
Reference fabric (grey)
Fig. 4-26
Defective fabric (mix-up of reference

yarn with a finer count yarn) (grey)
USTER QUANTUM 3
Count variations
Fig. 4-27
Reference fabric
Fig. 4-28

yarn with a finer count yarn)
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
Defective T-shirt (mix-up of reference

yarn with a coarser count yarn). Stripes
in the direction of the arrow
(see also Fig. 4-32).

yarn with a coarser count yarn)
USTER QUANTUM 3
Count variations
4.7.2
Reasons and measures to minimize count variations
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
Use autoleveller on finisher drawframe
Roving frame
Weight variation of rovings

Check roving trumpet hole diameter and cleanliness at the trumpet
input
Use different color of roving tubes to avoid roving count mix-ups
Ring spinning frame
Improper roller weightings

Spinning creel alignments
Dragging bobbin holders
Blocked spinning trumpet
False draft in ring spinning machine creel
Instruction and training of operators
Use of different colors of spinning tubes to avoid count mix-ups
Table 4-5
Preventive measures and tools for the management of long-term mass variations
Yarn Count Variation / USTER Tools for Improvement

Tools
Improvement
Constant quality control of sliver and yarn quality with the USTER
TESTER
Adjustment of autolevelling system
Separation of outlier bobbins with quality data software of the yarn

clearer

Correct settings of C and CC channel

Use C and CC alarm settings for eliminating wrong spinning bobbins

Table 4-6
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
Scatter plot of splices
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
Splice distribution. Measured yarn length: 216 km
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
Scatter plot of splices with the

clearing curves for thick/thin places and
splices
Fig. 5-3
Scatter plot of splices and thick/thin

places together
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
Examples of various scatter plots for splices.
Fig. 5-4
Optimum clearing curve for splices
Fig. 5-5
Clearing curve for splices too wide
Fig. 5-6
Clearing curve for splices too narrow in

the domain of thick places
Fig. 5-7
Clearing curve for splices too wide
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
Picture of several splices
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
Breaking elongation of splices, ring-spun yarn
The numeric test results were as follows:

Reference yarn
Splice
Ne 30, 100% CO, carded
Ne 30, 100% CO, carded
Strength [cN]
261
200
Variation of the strength [%]
9.91
23.0
Elongation [%]
4.66
4.87
Variation of the elongation [%]
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
Basic principles of splicing
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
Stages in splicing [2]
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
Splice structure [2]
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
Splice classification of the USTER QUANTUM 3
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
Display of splices (left) and splice classification (right)
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
Clearing limits for splice clearing (Jp and Jm)

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
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
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
Setting a smart clearing limit for splices (Jp/Jm)
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
Scatter plot of the cut faults and remaining events.
Number of expected fault cuts / 100 km

Clearing limit
Green dots = remaining events
Fig. 5-16
Jp settings adjustment to the scatter plot, thick places
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
Jm settings adjustment to the scatter plot, thin places
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
Jp/Jm yarn fault classification per winding position
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
Jp/Jm yarn fault registration
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
Machine summary display /JR Splice failure ratio
Upper yarn detection (U)
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%
For optical clearers:
60%
Fig. 5-21
Upper yarn detection (U)
USTER QUANTUM 3
5.13
Splice Clearing
5.7
5.7.1
Minimizing the number of splices

Critical items which affect the number of splices
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
40
Colored foreign fibers

20
Natural end breaks
0
6
100
Fig. 5-22
12
50
20
30
30
20
60
10
120 Nec
5 tex
Number of splices for a given number of cuts
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
Monitoring of splices with the USTER QUANTUM 3
Mean time between two splices
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
Natural end breaks
Thin and thick places
21
18
Total number of splices
63
Mean time between 2 splices per winding position
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
"Natural" end breaks
10
20
30
40
50
60
70
80
10
20
30
40
50
60
70
80
Number of splices
63
83
103
133
153
173
193
213
Table 5-3
Number of splices, conditions 1 to 8
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
Mean time between splices MTBS

(under the conditions mentioned above)
Mean time between splices MTBS at conditions 1 to 8
USTER QUANTUM 3
Splice Clearing
Fig. 5-24
Mean time between splices
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
Relationship between the productivity on winding machines and splices
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
Table 5-5 shows an example of a winding productivity calculation.

Winding
speed
[m/min]
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
Example of a winding productivity calculation
Fig. 5-25 is a graphical evaluation of 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
Periodic fault in cotton yarn resulting in a moir pattern
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
New periodic fault channel (PF) of the USTER QUANTUM 3
USTER QUANTUM 3
6.1
6.2
Influence of the yarn speed on the winding machine
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
Same faults detected

by the yarn clearer
because the yarn
speed on the winder
is not constant
Fig. 6-3
Difference between strictly-periodic faults at constant speed and variable speed
There is a more intensive effect of the drum on the variation of the periodicities in the short wavelength range.
6.3
Further reasons for periodic defects
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 fault registration with the PF
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
Setting for Periodic Faults (PF / Optional Q Data)
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
PF settings for detecting periodic defects
Fig. 6-5
Disturbing defects (so-called periodic

defects)
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
PF settings for detecting periodic defects
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
Taper board / Periodic fault on the left hand side
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
PF yarn fault report with PF faults
USTER QUANTUM 3
6.5
6
6.5
The effect of periodic faults on the fabric appearance
Mix-up of reference yarn with a yarn having periodic mass variation

Periodic mass variations in the yarn result in disturbing patterns in woven and knitted fabric. They are
never caused by the raw material, but are due to faults during fiber processing. Such faults must be
detected as early as possible. This type of fault is, however, extremely common. Mechanical parts
such as defective card clothing, eccentric rollers of drawing elements, defective aprons, etc., can all
produce periodic mass variations.
Thick or thin places can appear at regular intervals in woven and knitted fabrics according to the width
of the woven or knitted material and according to the wavelength of the periodic fault. These thick or
thin places result in unacceptable patterning and, in most of the cases, downgrade the finished fabric.
Fig. 6-9 shows two possible fault patterns and one optimum distribution in a woven or knitted material
caused by periodic mass variations.
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.
Another example of a yarn with periodic faults:

The condition of the rollers and the degree of ageing of the rollers affect the spinning performance.
Occasionally, cotton fiber producers suffer from infestations of aphids and other insects, which eventually produce contaminations such as sugars (honeydew) on cottons. Cotton fibers become sticky
and difficult to handle during processing due to these contaminations and cause fiber lapping problem
during processing [2]. Carelessness in cleaning lapped fibers on the rollers, especially during the
cleaning process when metal knives are used, can cause defects which leads to high unevenness.
The result will be an uneven fabric appearance. In our example, we have knitted ten rows of reference
yarn and ten rows of a yarn spun using defective top rollers to produce a periodic fault. There is a
significant difference between the CVm values, the thin places, thick places and neps values of the
two yarns (Table 6-1). When we compare the USTER STATISTICS values of the two yarns; the
CVm value of the reference yarn is equivalent to 61% of the USTER STATISTICS, the CVm value of
the defective yarn is more than 95% of the USTER STATISTICS. There is also a significant difference between the USTER STATISTICS values of thin places, thick places and neps of the two
yarns.
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 reference yarn measured with the USTER TESTER
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
Defective fabric (defective top rollers)
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
Reasons and measures to minimize periodic mass variations
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,
Incorrect setting of the piecing process (Comber)
Roving frame,
Eccentricity or defects of front top rollers
Ring spinning frame
Eccentric or defects front bottom rollers

Contaminated front rollers (honeydew, etc)
Table 6-2
6.8
USTER QUANTUM 3
PERIODIC MASS VARIATIONS / USTER Tools for Improvement

Tools
Improvement
Systematic Quality Control with the USTER TESTER
Use Periodic Faults option to separate bobbins with periodic mass variations

Monitor bobbins with periodic faults with the quality data software

Table 6-3
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
Frequent yarn faults and seldom-occurring yarn

faults
Fig. 7-2
Disturbing yarn faults were

discussed in chapters 3 to 6.
This chapter deals with frequent
yarn faults.
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:
yarn evenness (CV)
imperfections (frequent thick places, thin places and neps)
class alarm
hairiness
Fig. 7-3
Overview of quality characteristics
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.
The results are based on random samples.
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 results are determined at different speeds.
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
Starting from a bobbin change with selectable reference lengths
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
Definition of the coefficient of variation CV
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
Graphical representation of the CV
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
Reasons and effects of the yarn irregularity
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
High unevenness / mercerized / 100% cotton, combed, Nec 50
Fig. 7-6
7.2.3
High unevenness / mercerized cotton
Fig. 7-7
High unevenness / mercerized cotton,

magnified
Deviation of the CV mean value of a group of clearers (CVMV)
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
Deviation of the CV of a single winding position (CV-SP)
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
Schematic representation of the deviation behavior of the CV of an individual winding position
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
Setting window for the coefficient of variation at the Control Unit
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.
For data acquisition:

For the monitoring of the CV it is recommended to select the reference length of 100 m starting
from the bobbin tip (see "measurement"). As the yarn evenness increases from bobbin tip to
bobbin base, it is guaranteed that results measured under the same circumstances (same yarn
length) can better be compared with each other. A longer reference length is not recommended
as the number of faults increases at the bottom part of the bobbin and thus, the CV-value is influenced.
For pure data collection, no action is taken in case of exceeding limits.
For the selection of bad bobbins:

The selection of the reference length depends on the quality requirements. The reference length
must be derived from the possible CV-deviation in the yarn. The monitoring of faulty yarn must be
carried out continuously. This guarantees that bobbins which do not meet the quality requirements
will be monitored and can be taken out of the winding process (action: block). Mainly in the production of compact yarns, faults which are formed in the compacting zone can influence the CVvalue. Such faults can occur over the whole bobbin length.
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:
Murata Process Coner PC 21
Schlafhorst Autoconer 338
Savio Orion
Schlafhorst Autoconer AC5, ACX 5
Savio Polar
Alarm limit MV-monitoring

This is an absolute monitoring of the CV of a group. The CV mean value (CV-MV) alarm can only be
deleted by increasing the alarm limits or when the CV-MV decreases below the alarm limit. As no action is carried out in case of an exceeding limit, the alarm must be considered as a warning.
If the alarm limit is set to 0, the monitoring is inactive.
Monitoring of individual winding positions

With the monitoring of the CV of a winding position, a relative deviation of the single bobbin (SP-MV)
from the mean (CV-MV) is set. The setting of the percent value must be determined for each individual application. Due to the diverse causes for the changes of the yarn evenness, it is not possible to
give any recommendations for the settings.
The setting of an upper CV alarm limit which serves for the monitoring and detection of:
-
a high CV, caused by diverse faults in the production process

a rough ring
slow spindles caused by loose or contaminated drive belts or spindles drive belts
The setting of a lower CV alarm limit serves for monitoring and the detection of yarns, which have
too much twist caused by:
-
heavy ring travellers

2 ring travellers on one ring with different operating hours, i.e. the old traveller was not removed
twisted drive belts for spindles
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
Display of the CV values
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
Display of the CV-value
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
length: about fiber length
35%
50%
70%
100%
Thin place
length: about fiber length
-30%
-40%
-50%
-60%
Table 7-1
Imperfections, fault groups and classes

Thick and thin places have a relationship to the yarn evenness. The size and frequency of thick and
thin places has an influence on the yarn evenness. The higher the unevenness, the more frequent the
occurrence of thick and thin places.
An increase of the number of thick and thin places affects the quality of a yarn and has a disturbing
effect on the textile fabric. At the same time the increase is a textile-technological indicator for a deteriorating raw material quality, for worn-out card clothing in spinning preparation and worn-out key
components of the spinning machine. If such an increase occurs, the spinner can optimize the spinning preparation based on these data.
The occurrence of thick and thin places can of course not be prevented, but it is possible to reduce
the frequency and size of these faults.
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.
Raw material-related neps

Raw material-related neps which usually consist of dead and immature fibers often cause problems
due to different dye absorption in the dyeing process.
Nep, enlarged 44fold
Fig. 7-13
Nep, enlarged 360fold
Nep in a knitted fabric, scanning electron microscope photography
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.
Recommendation for the alarm limits of the imperfections:

An insensitive setting is:
Mean value (MV) of the imperfection classes + 5 standard deviation (s).
A sensitive setting is:
Mean value (MV) of the imperfection classes + 3 standard deviation (s).
Fig. 7-14
Setting of the alarm limits for imperfections
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
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
Display of the imperfection results
Fig. 7-15 displays the last measurement over the evaluation length with date and time of:
neps of all sensitivity levels per winding position
thick places of all sensitivity levels per winding position
thin places of all sensitivity levels per winding position
Furthermore, it displays the group mean value of all imperfection classes.
Fig. 7-15
Display of the imperfection counts
The results of the sensitivity levels will be marked in color in case of set alarm limits for certain classes.
green Alarm limit set but no alarm
red
7.4
Alarm, the set limit has been exceeded
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
Classification matrix at the Control Unit
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
Definition of the classes
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
CLASSIMAT matrix with the fault classes
Reasons and effects of the faults
The increase of the yarn faults can have different causes:
raw material related, i.e. a change in the raw material quality
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
Setting of the class-alarm at the Control Unit
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
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.
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
7.4.4
Display of the class alarms
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:
The set alarm was not reached.
ALARM:
The set alarm was exceeded.
In the lower part of the result window, the overall number of events corresponding to the chosen reference length is given.
Fig. 7-19
Display of the class alarms
The result of the class will be marked in color in case a set alarm limit was exceeded.
green Alarm limit set, but no alarm
red
7.5
Alarm, the set limit has been exceeded
Tailored classes (Option Advanced Classes)
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
Setting of the fault class
Tailored classes for NSL, T and FD can be defined.

The settings are: Sensitivity (%) and the length (cm) values of the upper right and lower left corner for
the tailored classes NSL, T and FD.
Fig. 7-21
7.20
Setting of tailored the fault class
USTER QUANTUM 3
7.5.2
Display of the tailored classes
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
iMH LED Display Function for tailored classes
USTER QUANTUM 3
7.21
7.6
Adjustment of the individual alarm possibilities
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
Principles of operation of the hairiness measuring systems
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
Yarn hairiness in garment / 100% cotton, combed, Nec 32 (18,5 tex)
Fig. 7-28
Yarn hairiness in garment, zoomed

picture
The following 100% bleached cotton T-shirt (Fig. 75 and Fig. 76) also shows excessive hairiness.
Fig. 7-29
Yarn hairiness in cotton T-shirt / 95%

cotton / 5% polyurethane,
Nec 34 (17,4 tex)
Fig. 7-30
Yarn hairiness in cotton T-shirt
Measuring method of the USTER QUANTUM 3

For the USTER QUANTUM 3, a similar measuring method as for the USTER TESTER 4 was chosen. The prerequisites for the hairiness measurement are given by the foreign fiber measuring field.
However, the evaluation of the signal had to be adjusted. The highest attention was put on the reproducibility of the deviations from the mean value to detect outlier bobbins.
7.24
USTER QUANTUM 3
7.7.2
Settings
Fig. 7-31
Setting of the hairiness parameters at the Control Unit
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.
For data collection:

For the monitoring of the hairiness, it is recommended to select a reference length of 400 m starting from the bobbin tip (see "measurement"). As the yarn hairiness increases over the bobbin
length, it is guaranteed that results measured under the same circumstances can be compared
with each other. A longer reference length is not recommended, as the hairiness increases at the
bottom part of the bobbin. For pure data collection, no action is taken in case of exceeding limits.
For the selection of bad bobbins:

The selection of the reference length depends on the quality requirements. The reference length
must be derived from the expected hairiness deviations of the yarn. The monitoring of faulty yarn
must be carried out continuously (see section "Measurement" below). This guarantees that bobbins, which do not meet the quality requirements, can be taken out of the winding process (action:
block). In case of compact spinning it is particularly the compacting zone in the case of compact
spinning which can considerably influence the hairiness. Such faults can affect the hairiness over
the whole bobbin length.
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
Schlafhorst Autoconer 338
Savio Orion
Schlafhorst Autoconer AC5
Savio Polar
MV-monitoring (group mean value)

Upper alarm limit H MV:
Lower alarm limit H MV:
0,1 20.0
0,1 20.0
SP-monitoring (winding position)

Deviation of the SP-monitoring from the group mean value.
Upper alarm limit SP:
Lower alarm limit SP:
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
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.
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
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
Display of the hairiness values
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
Display of the Hairiness value
SP UPPER ALARM LIMIT

The indicated upper absolute hairiness alarm limit is calculated from the hairiness mean value of
the group and the preset upper hairiness alarm limit.
SP LOWER ALARM LIMIT

The indicated lower absolute hairiness alarm limit is calculated from the hairiness mean value of
the group and the preset lower hairiness alarm limit.
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
How do hairiness variations affect woven and knitted fabrics?
Uster Technologies has investigated various aspects of hairiness in order to clarify the effect of hairiness variations on fabrics.
Patterns in the fabrics

First test: The effect of hairiness variation on woven fabrics was investigated after dyeing. Fig. 7-33
shows the consequences on a fabric consisting of 100% cotton in the weft. The yarns with various
hairiness values were inserted in the weft. The four yarns were of the same count but had different
hairiness values of 5.7, 6.9, 7.9 and 9.0.
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
Hairiness monitoring on the machine
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
On-line tests versus off-line tests
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
Comp Sssen 20Tex
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
Basic hairiness differences between the different spinning methods
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
Hairiness variation of yarns produced by various spinning systems
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
blue: bobbin tip red: bobbin base
Fig. 7-36
7.7.8
6 measurements, 400 m per bobbin, through the bobbins
Practical examples
Hairiness monitoring on ring-spun yarns

On a winding machine, 460 bobbins were tested regarding the hairiness. Yarn: Nec 30, 100% cotton,
combed, ring-spun yarn.
Fig. 7-37 shows the results of a series of measurements of 460 bobbins. It can be clearly recognized
that the hairiness results are scattered around the mean value of H = 4,8. Furthermore, there are 5
winding positions with a hairiness beyond the set limits.
Outlier winding positions
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
Measurement of the hairiness of a conventional ring-spun yarn
USTER QUANTUM 3
7.31
Abbreviations
H
= Single value for the hairiness
H-MW
= Mean value of the hairiness of the group
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
Hairiness monitoring of compact yarns

On a winding machine, 160 bobbins were tested regarding the hairiness. Yarn: Nec 50, 100% cotton,
combed, compact yarn.
Fig. 7-38 shows the results of a measurement of 160 bobbins of compact yarn. In comparison to the
measurements of a ring-spun yarn shown in Fig. 7-37, the values are located much closer around the
mean value. Furthermore it can be seen that the mean value of the hairiness is much lower than the
mean value of conventional ring yarn. This was also experienced with off-line measurement.
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
Hairiness measurement of a compact yarn
Abbreviation:
H
= Hairiness
MW-group
= Hairiness mean value of the 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
Indication of ejected bobbins
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
Criteria to select the limits for quality characteristics
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
Frequent thin places
Periodic faults (pearl chains)
Frequent thick places
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
In week 10 a massive increase in the hairiness can be noticed.
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
Selected limit for

separating bobbins
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
Installation of a quality management system to eliminate outliers
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 shows the principles of operation in a modern spinning mill.
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
Recommendations for a systematic quality management
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
Tracing back outlier bobbins to the source
Bobbin identification method

The easiest way to trace back outlier bobbins is the designation of each bobbin with the number of the
spinning position. This identification can be realized for one ring spinning machine within 20 minutes.
Fig. 7-43 shows the identification of the bobbins.
Ejected bobbins from

winding machine
Entry of marked spindle

in action plan
Laboratory
Marking of spindle
position
Fig. 7-43
Action plan
for repair crew
Identification of spinning positions for one doff
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
Systematic repair of defective production positions
Lessons learned with the first systems in mills:
The yarn monitoring system on the last machine in the spinning process
also has to check the quality characteristics.
The monitoring of the quality characteristics on the winding machines

offers new opportunities to considerably lower the daily outlier bobbins.
Modern on-line systems support spinners to keep the quality of every

yarn package within pre-set limits.
Outlier bobbins produced by non-identified spinning positions

As has been mentioned above, the bobbins of all spinning positions are identified once in 20 to 30
days. This method allows a precise tracing back of outlier bobbins to the source of the problem.
However, in a spinning mill with 25 ring spinning machines there are 24 machines which deliver nonidentified outlier bobbins to the laboratory via the winder at a certain date. If there is a clear assignment in the mill what kind of bobbins were processed on what winding machines, it also allows the
assignment of the type of problems at least to a specific spinning machine.
If a spinning mill uses link systems, the back tracing of the bobbins to the ring spinning machine is
easy. In spinning mills with stand alone winders it depends on the organization of the mill.
Example: If more and more non-marked bobbins exceed the hairiness thresholds, it may be time to
replace the ring travelers.
USTER QUANTUM 3
7.37
7.9.3
Examples from the industry
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
Wrong direction of apron, bad joint
Fig. 7-48
Intensive contamination at output of

drawbox
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
Recommendations for a sampling plan
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:
Long maintenance cycles for clearers
Contamination of the measuring zones of on-line systems as a result of a permanent monitoring,

24 hours a day, 7 days per week
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
Time required also includes setting of instrument and sample preparation

The amount of 60 ejected bobbins per day is equivalent to 0,022% of the daily production or 3,5 kg of yarn (Basis: Nec
30).
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
7.10.1 Reasons and measures to minimize random mass variations

In Table 7-3, the origin of faults related to random mass variations is given. Possible reasons and
preventive measures to avoid such faults are explained and various USTER tools for improvement
are presented.
RANDOM MASS VARIATIONS
Origin of Faults
Card
Regular maintenance
Drawing
frame
Apply autoleveller at finisher drawframe /

Regular maintenance of drawing elements
Roving
frame
Incorrect setting of the roving traverse
Ring spinning frame
Incorrect break drafts

Dimension of apron
Aprons change schedule and quality of
aprons
Excessively worn aprons
USTER QUANTUM 3
7.41
RANDOM MASS VARIATIONS

Origin of Faults

Top roller grinding schedule
Top roller hardness
Cot condition and hardness
Roll chatter
Top roller minimum diameter
Dimension of spacers
Training of operators (avoid cutting top
roller)
Yarn diameter differences
Excessive balloon tensions
Incorrect roller settings
Top front rollers are out of position
Pigtail centering
Worn rings
Periodic mass variation from previous
processes
Roller weightings
Improper apron spacing
RANDOM MASS VARIATIONS / USTER Tools for Improvement

Tools
Improvement
Constant quality control of sliver and yarn
quality with the USTER TESTER (spectrogram)
Adjustment of autoleveller
Proper setting of the pearl chain option

for alarms

Separate bobbins with high CVm with

quality data option
The quality data setting for CVm can be
used to separate bobbins with high CVm
Table 7-3
7.42
Monitor long-term variation of cut ratio

and yarn quality
Preventive measures and tools for the management of random mass variations
USTER QUANTUM 3
7.10.2 Reasons and measures to minimize imperfections

Uneven fabric appearance is the result of too many thin places, thick places and neps. There are various reasons for an excessive formation of imperfections. In this section, some of these reasons will
be explained with the help of pictures of the knitted samples and their yarn quality results.
Mix-up of a reference yarn with a yarn of a high imperfection level

During compact yarn production, the air suction area in the compacting zone can become clogged for
a variety of reasons. This affects the spinning process in a negative way and can increase the number
of imperfections and especially neps. In our example, we have tested a reference compact yarn and a
defective compact yarn arising from a clogged compacting zone. If we check the CVm values, thin
places (-50%), thick places (+50%) and neps (+200%) of the two yarns, we can see a significant difference. In particular, the number of thin places (-40%), thick places (+35%) and small neps (+140%)
have increased significantly (Table 7-4).
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
Fabric simulation of reference compact yarn
Fig. 7-50
Fabric simulation of defective compact

yarn
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
Thick places & Thin places

Comber
Excessive short fiber content
Roving frame
Lint or fly on roving
Ring spinning frame
Lint build up on drafting rolls

Blown in lint
Apron and cot conditions
Apron spacing
Out of position top front roll
Incorrect roving traverse
High balloon tensions
Loaded travelers
Draft distributions (break draft)
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
Nep levels in roving

Apron worn out
Tensor pin opening
Ring and traveler worn out
Improperly set traveler clearers
Balloon control ring worn out
Raw material:
Length uniformity
Short fiber content
High micronaire variations
High level of neps
YARN IMPERFECTIONS / USTER Tools for Improvement

Tools
Improvement
Proper bale management and laydown management
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
Monitor long-term variations of cut ratio and yarn quality

Table 7-5
Preventive measures and tools for the management of yarn imperfections
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.
Different ring spinning techniques

In this trial, two different ring spinning techniques were compared on the same T-shirt sample: conventional ring spinning and the compact spinning technique. We have knitted 10 rows of reference
yarn (conventional, Nec 36, 16,5 tex) and 10 rows of a compact yarn (compact Nec 36, 16,5 tex) spun
from rovings produced from the same cotton blend. We can observe horizontal dark and light colored
lines in the T-shirt sample. These horizontal lines are the result of yarn hairiness difference (Fig. 7-51
to Fig. 7-54). This significant difference can also be observed in Table 7-6.
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
Defective fabric (mix-up of compact

yarn)
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
Spinning preparation, spinning and winding
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
EXCESSIVE HAIRINESS / USTER Tools for Improvement

Tools
Improvement
Systematic quality control of sliver and yarn quality with
USTER AFIS system (short fiber content) and USTER

TESTER, hairiness sensor
Use quality data settings for hairiness to separate spinning bobbins with excessive hairiness

Table 7-7
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
Separated foreign material in cotton
USTER QUANTUM 3
Fig. 8-2
Separated foreign material in cotton
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
Plastic fibers in card sliver
Fig. 8-4
Plastic fibers in card sliver
Various foreign fibers in yarns at different magnification / inorganic material
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
Examples of various dense areas:
Fig. 8-7
Examples of various dense areas:
Fig. 8-8
8.4
USTER QUANTUM 3
Foreign fibers
8.3
Foreign fibers
8.3.1
Types of foreign material in cotton
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
seed coat fragments
cotton boll
woven plastic
packing material
jute
packing material
plastic fragments
foreign matter blown into the fields
strings
for cotton bags
bird feathers
natural contamination
grass
contamination during harvesting
paper
contamination of cotton fields
leather
human and animal hair
contacts with humans and animals
rust
machines or transportation trucks
metal plates / wires
oil / grease
machines or transportation trucks
rubber
stamp colorant
identification of bales
tar
Contamination of natural and manmade origin
Table 8-1
Contaminations found in cotton (Source: ITMF 2009 [5])
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
lubricant residue on machine parts (grease or oil)
a messy working environment with dust and dirt
dust or very small particles from rubberized machine parts (e.g. press rollers) or drive belts, which
adhere to the yarn
Transport vehicles which were not cleaned when moving cotton.
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
Example of grease in the yarn
Vegetable matter
With vegetable matter, it is necessary to clearly differentiate between two categories
pieces of vegetables
vegetable packing material
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
Examples of seed-coat fragments
USTER QUANTUM 3
8.7
Foreign fibers
Vegetable packing material

Foreign matter made out of vegetable packing materials is e.g.:
jute fabric or jute-/hemp strings
chemical components based on cellulosic material
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
Examples for vegetables in the yarn
Degree of contamination of bales
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
Size and appearance of foreign matter in spinning mills
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
Foreign material at various stages of the spinning process
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
Frequency of foreign fibers in spinning mills
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
* Average distance between 2 foreign fibers
Ring spinning
machines
Winding
machines
*100 to 300 m
Fig. 8-16
Effect of drafting on foreign fiber distribution in yarns
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
Foreign fiber risk calculated for a spinning mill
Fig. 8-17 shows the risk of a spinning mill which has the foreign fiber challenge not under control.
34800
36000
32000
Sales prices in USD
28000
24000
18000
20000
16000
12000
7320
8000
3840
4000
600
1320
0
Bale
Fig. 8-17
Yarn (Nec 30,

combed)
Raw fabric
Finished fabric
(bleached)
Shirts
Retailer
Foreign fiber risk calculated for a spinning mill
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
Classification matrix of foreign fibers with the USTER QUANTUM 3
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
Low degree of contamination per 100 km
Heavily contaminated
per 100 km
Combed yarns, 100% cotton
10
150
Carded yarns, 100% cotton
20
300
Worsted yarns, 100% wool
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:
the more disturbing are the consequences in the fabric
the lower is the number of this kind of faults in the yarn
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
Less sensitive setting: many remaining faults, but less splices
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
General references for foreign fiber clearing
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
Distribution of foreign fibers in a cotton yarn
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
Clearing limits for dark foreign fibers in light yarn
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
Diagram for the optimization of foreign fiber clearing
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.
This means after we entered the values for FD1, set point FD2 will appear and it will continue the
same way.
Fig. 8-21
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
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
Setting a smart clearing limit for dark foreign matter (FD)
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).
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
Blue dots are remaining events
Dense area
= Proposes the starting point
for the clearing limits based on the
dense area.
Fig. 8-22
Display of the dense area
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
Setting page for FD manual setting or

setting by smart limits available
USTER QUANTUM 3
Fig. 8-24
Display of dense area
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.

=
Show dense area and

scatter plot
= confirm and activate optimized

clearing limit.
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
Foreign fibers and their effect on the various production processes
What is understood by foreign fiber detection?

Commonly, under the term foreign fiber detection, textile specialists understand the elimination of all
foreign matter in a yarn, which exhibits a contrast to the yarn. With the existing technology, a real color measurement is not possible. Therefore, the evaluation of the light/dark contrast was chosen.
Very short foreign fibers with the same extension like seed coat fragments must be left in the yarn as
they are not disturbing and because of the high number of cuts that has to be expected and because
such fibers can hardly be recognized in a fabric.
The decision for the respective clearing limit must derive from the principle that no long foreign fibers
should remain in the yarn. The maximum admissible length of the foreign fibers which may remain in
the yarn depends on the final purpose of the yarn. Particularly critical are unicolored large fabric such
as bed sheets, table sheets, etc.
Measuring principle and evaluation

For the monitoring of foreign fibers, an optical measuring system is used. For this, a comparison between the reflection deviation of the foreign fiber and the normal yarn color is measured. This means,
that a very dark foreign fiber in a very light yarn produces a higher contrast than the same foreign
fiber in a yarn made out of gray fibers.
The difference between the actual yarn color and the contrast of a foreign fiber and its length, over
which the color change occurs, is measured. These two values (reflection in % and length in cm) are
compared with the set clearing limits. Are both values above the clearing limit, a cut is carried out.
Foreign fibers which do not exceed the clearing limit are entered in the classification matrix.
Structure of the classification matrix

Fig. 8-27 shows the structure of the classification matrix for foreign fibers. The foreign fibers are classified by the parameters reflection (%) and length (cm).
USTER QUANTUM 3
8.19
Foreign fibers
Fig. 8-27
Structure of the classification matrix for foreign fibers
Fig. 8-28 shows a practical example for a classification matrix of a carded cotton yarn.
Fig. 8-28
Practical example for a foreign fiber matrix
Foreign fiber grades

The graphical representation of disturbing foreign fibers and their classification cannot be done the
same way as for disturbing thick and thin places, i.e. as generally accepted grades. Depending on the
degree of contamination of the raw material, certain colors and frequencies can dominate in the cotton from certain growth areas, whereas other growing regions have completely different foreign fibers.
Therefore, it is recommended to generate such grades depending on the respective fiber blend internally, in order to obtain certain standards for the existing foreign fibers.
8.20
USTER QUANTUM 3
Foreign fibers
8.6.1
Methods to eliminate foreign material and frequency of foreign material
A comparison of frequency of foreign material and elimination methods

Fig. 8-29 shows the domains of foreign material removal systems and the frequency of foreign material. It is obvious that the frequency of foreign material increases considerably in the area of fine foreign matter (human and animal hair, plastic fibers, fragments of strings, seed coat fragments).
Frequency of
foreign material
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
Methods to eliminate foreign material in cotton and foreign material frequency
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:
Selection of cotton with small amount of foreign fibers
manual labor to pick foreign matter in cotton prior to the opening
foreign matter removal systems prior to the card
foreign fiber clearers on winding machines
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
Manual removal of foreign material in a Chinese spinning mill
Foreign material removal systems prior to the card

There are various foreign material removal systems available today prior to the card. In general such
devices are important to eliminate the foreign matter of a size greater than 0.5 cm2 to avoid further
disintegration into finer fibers which would increase the cuts in the final inspection by the yarn clearers.
However, such systems do not fully meet the quality targets of the end user since the size and the
number of ejections make it practically impossible to eliminate the single foreign fibers which constitute the highest amount of disturbing defects in the final yarn or fabric. Further, the location of the system and the size of the tuft play a decisive role for the detection efficiency. Similar to manual elimination, the electronic removal systems help in reducing major contaminations, finally reducing cuts and
human intervention in winding. This helps to maintain consistency in cuts.
Foreign fiber clearers in winding

Foreign fiber clearers are by far the most efficient systems to solve the contamination problems. With
the improvement of the detection rate by the USTER QUANTUM 3, the solution has become more
and more popular. Today about 75% of delivered clearers are with foreign fiber functionality for cotton
yarn measurement.
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
Contaminations found in cotton
Calculation of a practical example:

Assumption:
Spinning mill with 30000 spindles
Production per day: 15000 kg
Yarn count:
Nec 30
Subject
Ejections prior to card per opening/cleaning line
Calculation method
Result
1200/24 hours
960 foreign items
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
1920 foreign items
1/100 km
25 per 100 km
of yarn
Winding duration per

100 km: 100000 / 1400
71,43 min
25 1440 / 71,43
504 cuts
600 504
302400 cuts
Calculation of foreign material detection
USTER QUANTUM 3
8.23
Foreign fibers
Conclusion per 24 hours, entire mill:

Ejection of real foreign matter:
1920
Number of foreign fiber cuts:
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.
Mending of defects in weaving/knitting

Mending of the woven fabric by removing the disturbing foreign fibers is also a common practice, especially in composite mills. However, as a practice this is possible only if the defect frequency is low.
Further, this also results in costs and claims to the spinner. Some estimates mention USD 6 to 10 /
100 m as mending costs in low cost countries depending on the amount of defects.
For knitted fabrics, mending is not recommended since they damage the fabric. Defects that have a
higher defect rate or mending requirement are often sold for other low end applications, e.g. printed
furnishing.
8.6.2
Effect of large foreign particles on the spinning process
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
Alarm options for frequent foreign fibers in yarns with clearers
The following are the methods to eliminate clusters of foreign fibers:
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
Limits of foreign fiber elimination
Ring spun yarn

Table 8-4 shows an average number of splices in a ring spinning operation. This mill eliminates 30
foreign fibers per 100 km.
The total number of splices is 92,5 per kilometer. At a winding speed of 1200 m/min the mean time
between 2 splices per winding position is 0,9 minutes.
Assumption: Count Nec 30, combed cotton, bobbin size 70 g, winding speed 1200 m/min. All figures
calculated per 100 km.
Bobbin changes
28,5
"Natural" end breaks
4,0
Thin and thick places
30,0
Foreign fibers
30,0
Total number of splices
92,5
Mean time between 2 splices per winding position
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
Benchmarks for end breaks

(Central Europe)
End breaks caused by foreign

matter (experience values)
Beaming
0.2 to 0.3 per 1'000'000 meters
up to 50%
Weaving
1 to 2 per 100'000 picks
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
Recommended approach to eliminate foreign fibers
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
Field tests in China
Test procedure
A field test was carried out in a quality oriented Chinese spinning mill, where the following foreign
matter removal systems were available:
Electronic foreign material elimination system prior to the card
Visual elimination of foreign material prior to the card (70 employees)
Yarn clearer (USTER QUANTUM 3) with foreign fiber feature.
The mills had the following standards:
Knitted fabric - 10 defects/ 20 kg
Woven fabric 28 defects / 100 square yards
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
Fabric inspection for foreign fibers at Litay
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
Visual check and

removal system
prior to card
st
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
Comparison with the efficiency of the 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
With removal systems prior

to card and yarn clearer
Application of all elimination systems
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
Comparison with the efficiency of the 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
With removal systems prior

to card and yarn clearer
Application of all elimination systems
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
Foreign fibers and their effect on the fabric appearance
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
Example of a foreign fiber in a woven fabric
Fig. 8-40
Example of foreign fibers in a knitted fabric
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:
Short, clearly visible colored foreign fibers in a range of 2 to 3 loops
Longer, light foreign fibers starting in a range of 8 to 10 loops
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
Foreign fiber in knitted garment / 100%

cotton, combed, Nec 46 (13 tex)
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
Foreign fiber in mens cardigan / 100%

Fig. 8-46
Foreign fiber in mens cardigan / 100%

Reasons and measures to minimize foreign fibers in yarns
In Table 8-6 and Table 8-7, the origin of the faults related to yarn contaminations is given. Possible
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
Controlled recycling of waste
Cards
Efficient carding and combing
Drawing frame
Proper blending at all drawframes
Combing
Optimize comber settings (comber noil, processing speed) in order to

achieve the maximum foreign fiber reduction.
Table 8-6
USTER QUANTUM 3
8.33
Foreign fibers
CONTAMINATION / USTER Tools for Improvement

Tools
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

Table 8-7
8.34
Long-term control of quality level
Preventive measures and tools for the management of foreign fibers
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
With vegetable matter, it is necessary to clearly differentiate between two categories
pieces of vegetables
vegetable packing material
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
Vegetable packing material

Foreign matter made out of vegetable packing materials is e.g.:
jute fabric or jute or hemp strings
chemical components based on cellulosic material
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
Examples for long vegetables in yarns
Distribution of vegetables and foreign fibers
In order to differentiate between vegetables and foreign fibers, different possibilities were tested. The
chosen approach was:
A fine foreign fiber has a low reflection and a low mass
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
Dense area for vegetable matter (VEG)
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.
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

Fig. 9-5
plot for foreign matter (inorganic matter only)
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
Separate limits for inorganic fibers and organic matter
USTER QUANTUM 3
Fig. 9-7 shows how the foreign matter can be separated into inorganic foreign fibers and vegetable
matter.
Scatter plot containing

inorganic and vegetable
matter (FD Clearing)
Scatter plot containing only

inorganic fibers (VEG Clearing)
Matrix of foreign matter showing clearing curve for inorganic matter (VEG Clearing)
Fig. 9-7
Scatter plot containing only

vegetable matter (VEG Clearing)
Matrix of vegetable matter showing both clearing curves

for inorganic and vegetable matter (VEG Clearing)
Separation of inorganic and vegetable matter
USTER QUANTUM 3
9.5
9.3
Classification matrix of vegetable matters with the USTER QUANTUM 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
Setting a clearing limit for vegetable matter (VEG)
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.
VEG clearing limit

Brown dots are remaining
vegetables.
Dense area
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
Vegetable matters and their effect on the fabric appearance
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
Reasons and measures to minimize vegetable matter in yarns
VEGETABLE MATTER CONTAMINATION
Origin of Faults

Prefer when possible to use cotton with low content of foreign fibers
and vegetable matter.
Bale management

Blowroom
Optimize and control the settings and maintenance of the blowroom machines
Cards
Drawing frame
Combing

Table 9-1

Tools
Improvement
Quality control of foreign fibers and vegetable matter with USTER

TESTER when dealing with new raw material
Proper setting of foreign fiber and vegetable matter detection

settings

Table 9-2
Preventive measures and tools for the management of foreign fibers and vegetable matter
USTER QUANTUM 3
9.11
9.12
USTER QUANTUM 3
Detection of polypropylene fibers with 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
Examples of PP fibers taken with a scanning electron microscope / OE rotor yarn
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
Examples of polypropylene fibers / Optical microscope photography
Fig. 10-3
Polypropylene fiber in a knitted fabric before dyeing
10.2
USTER QUANTUM 3
Fig. 10-4
10
Polypropylene fibers in a knitted fabric after dyeing
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.
10.1.1 Configuration of a PP-clearer

For polypropylene clearing the measuring head C15 or C20 can be used, with foreign fiber sensor
and additional polypropylene feature. A software upgrade for PP clearing is not possible, as it requires
hardware changes in the Central Clearing Unit (CCU) only.
Fig. 10-5
Configuration of a USTER QUANTUM 3 with PP

clearing / Required options / Clearer iMH C15F30 or
C20F30
USTER QUANTUM 3
10.3
10
10.1.2 Frequency of PP fibers

The PP fibers are much less common than colored foreign fibers. Trials have shown that the frequency of PP fibers is about 5 20% compared to colored foreign fibers as a rough estimate.
In the table below, there are experience values of the ratio of polypropylene cuts to the cuts of thin
and thick places and conventional foreign fibers. It can be seen that even with additional cuts caused
by the PP clearing, the clearing efficiency only changes insignificantly.
Reasons for splices
Splices / 100 km
Number of bobbin changes
34
Disturbing thin and thick places
30
Conventional foreign fibers
30
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
100% cotton, Nec 14, carded
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
100% cotton, Nec 20, combed
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
100% cotton, Nec 30, compact yarn with PP fibers
10.1.3 Application range of PP-clearing, ring-spun yarn

Yarn types
At the moment, PP clearing can be used for 100% combed and carded cotton yarns, compact yarns
included.
iMH Types - All capacitive clearers C15 F30 and C20 F30 / The PP efficiency of C15F30 is higher
Count range Same as the range for 100% cotton yarns for C15 and C20
Speed No restriction
Length No hard limit
Humidity range - No hard limit
Fig. 10-10
10.6
Count range of polypropylene detection
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
Range of yarn counts produced worldwide, ring spun yarn.
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
Frequent and seldom-occurring yarn faults. Measured yarn length: 2298 km
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
Examples of various scatter plots
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
Yarn Ne 60, 100% cotton, combed,

weaving, 1952 km. High amount of PP
fibers: 7,2 PP fibers per 100 km
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
Yarn Ne 60, 100% cotton, combed,

compact, weaving, 2254 km. High
amount of PP fibers: 6,6 PP fibers per
100 km
10.8
USTER QUANTUM 3
10.3
10
Clearing limits for polypropylene fibers
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.
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
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
10.3.2 Setting a smart clearing limit for polypropylene fibers

Polypropylene defects are very disturbing, especially in dark dyed fabric. With the PP option the
USTER QUANTUM 3 can detect white or colored polypropylene fibers coming from bale packing
material and other sources. Polypropylene fiber contaminations are well visible as white fault after
dyeing of the finished cloth because the polypropylene fiber doesnt absorb cotton dyestuff. The PP
feature detects polypropylene in cotton yarn during winding.
But it is not just restricted to appearance issues. Similar to regular foreign fibers, polypropylene defects can also cause breaks in weaving preparation or on looms. Polypropylene elimination capability
is slowly becoming a crucial flexibility for spinning mills to meet higher quality needs. Thanks to technological improvements, the USTER QUANTUM 3 has a high polypropylene detection rate and at
the same time spends relatively less cuts to remove them. This has been proven with several field
trials which have consistently shown a high removal efficiency of polypropylene including short and
fine PP fibers with high cut efficiency.
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. 10-18). Besides the scatter plot, the cut faults and remaining events and the number of expected fault cuts per 100 km can be seen on the screen. The used setting limits will appear directly on
the same setting page (Fig. 10-18).
Pressing
key presents
Scatter plot of the cut faults and remaining events.
Number of expected fault cuts / 100 km.
Clearing limit
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

= Show scatter plot
= confirm and activate optimized clearing limit.
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
PP yarn fault registration
USTER QUANTUM 3
10.11
10
10.4
Polypropylene fibers and their effect on the fabric appearance
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
White polypropylene fiber, turtleneck,

knitted / 100% cotton, combed,
Nec 34 (17,5 tex)
Fig. 10-22
Magnified PP fiber in turtleneck
USTER QUANTUM 3
10
10.4.1 Reasons and measures to minimize foreign fibers in yarns

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. Particularly the use
of polypropylene bags should be avoided.
Blowroom
Cards
Drawing frame
Combing

Table 10-2

Tools
Improvement
Quality control of foreign fibers with USTER TESTER when dealing with
new raw material
Proper setting of foreign fiber detection
settings
Table 10-3 Preventive measures and tools for the management of foreign fibers
USTER QUANTUM 3
10.13
10
10.14
USTER QUANTUM 3
Various settings and applications of USTERQUANTUM 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
Comparison of different clearing limits and article settings
11.1.1 Comparison of various clearing limits

The USTER QUANTUM 3 gives the chance of comparing up to three different clearing limits on the
same yarn body. These three limits are presented in Fig. 11-1, with different colours:
Red = Active clearing limit for a yarn which is currently on the winder (Fig. 11-1)
C1, Dark blue = Clearing limit for a yarn which has a yarn count of Ne 34, Article name is Geneva
(Curve 1 in Fig. 11-1)
C2, Light blue = Clearing limit for a yarn which has a yarn count of Ne 40, Article name is Sydney
(Curve 2 in Fig. 11-1).
As it can be seen in the example Fig. 11-1, the user can compare 2 various clearing limits with different names to his current clearing limit.
Selection of
clearing channel
Selection of article
Article
Active clearing limit = red

Curve 1 = dark blue
Curve 2 = light blue
Display of the
clearing limit from
2 other articles
Fig. 11-1
Comparison of various clearing limits
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
Comparison of current modified article settings to the original article settings
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
Comparison of the chosen smart limit to original article clearing limit
USTER QUANTUM 3
11
11.1.2 Recreate or recall of the factory settings of the default articles

Up to version release 1.01.05, it is possible to recall the factory settings of the two default articles (capacitive and optical default). To recreate the default article again, the user can select and copy any
article by pressing 'Copy article' button. After that create a new article option should be chosen (Fig.
11-4, left) and confirmed. However it is also possible to reset an existing article to the factory default
settings. For this, the user should choose the article that should be reset in the 'Copy to' selection box
instead of creating a new article (Fig. 11-4, right).
Fig. 11-4
11.2
Recalling the factory settings of the default articles (capacitive (left)and optical (right))
Display of Data and Alarms
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
Machine summary submenu in the Display main menu
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
Group settings of the winding machine
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 fault total YF
Yarn alarms YA
Quality alarms QA
Foreign fiber F
Foreign fiber alarms FA
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
Definition of exception report in the Reports main menu
11.2.3 Display of yarn faults with the help of textile alarms

With the USTER QUANTUM 3, it is possible to define and display textile alarm limits in the settings
main menu. A textile alarm is triggered when the set number of yarn faults per reference length is
reached. The winding position will be blocked and the iMH LED lights up continuously. The setting
parameters are number of faults and the reference length in km.
Fig. 11-9
Definition of yarn fault alarms in the Settings main menu
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
Clear counters of a group
11.6
USTER QUANTUM 3
Fig. 11-10
11
Textile alarms submenu in the Display main menu
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
Textile alarms (left) and technical alarms and warnings (right)
Explanation of textile alarm types:

Textile Alarm
Quality Alarm
Explanation of technical alarm and warning types:

Warning
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.
11.3.2 Event display by the red light at the sensor (iMH-LED)

The two LEDs at the iMH are used for the display of textile and technical alarms. Furthermore, it is
possible to show the status of the clearer installation, especially during a lot change or during start-up
of the installation.
In addition, the LED can be used for the display of cut events. This can be very helpful, when certain
yarn faults should be removed for visual examination.
After the setting of the corresponding function code at the Central Clearing Unit, the iMH-LED displays the code as soon as the desired cut type is triggered. The LED can be deleted by pressing the
iMH-button or it switches off automatically when the winding position is started again.
On new winding machines, the winding position automatically switches to "test mode". This means,
that the winding position will be stopped until it will be turned on again manually.
This is valid for the following machine types:
Schlafhorst AC-338
Schlafhorst AC-5 and ACX5
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 iMH cuts
iMH LED flashes according to the selection
red winding position lamp lights up continuously.
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
iMH LED Display Function
Explanation: The iMH-LED is turned on, when a N, FD or PP-cut is triggered.

In the event report (Fig. 11-12, right), the yarn faults / cuts are also displayed showing the size / intensity in % and length in mm, as well as their classification. The events which should be displayed have
to be selected in the Configuration Menu (Valid up to Release 1.01.05, for higher release numbers
this will not be necessary anymore, Fig. 11-13, left). The selected events are displayed with date, time
and winding position information (Fig. 11-13, right).
Fig. 11-13
Configuration menu (left) and Event Reports menu (right)
11.3.3 Yarn fault cards

Yarn fault cards are an easy and very helpful instrument for the collection of yarn faults and their
evaluation. The displayed yarn faults provide a very good impression about the existing faults. By
means of the visualization the user can decide which faults can remain in the yarn and which faults
have to be cut. This depends also on the final product.
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:
clearing limits can be better determined and optimized
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.
Yarn: Ne 30, 100% cotton, combed, bobbins

Sensor: iMH C15F30
S-faults
Fig. 11-14
Yarn: Ne 30, 100% cotton, combed, bobbins

Sensor: iMH C15F30
FD-faults
USTER yarn boards, thick places (left), foreign fibers (right)
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
Monitoring of winding functions
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:
Upper yarn (U)
Drum sensor (DSM)
Splice (Joint, J)
Drum wrap (DWM)
Yarn jump (JPM)
Cut (CTM)
Zero point (ZPM)
The display of the group settings can

change according to the winding machine
type. The following additional parameters
can be seen on the display:
Speed: manual winders only
Startup time: manual winders only
Dont cut drum wrap (Orion (Polar only),
Espero, Smaro, Spero
DSM Drum Signal monitoring (most machines)
Dont cut drum wrap (Orion (Polar only),

Espero, Smaro, Spero
Fig. 11-15
Group settings of the winding machine
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
JRA Splice failure rate alarm

The splice failure rate in % is a relation between total splices and splice cuts (Jp + Jm). A textile alarm
occurs and the LED of the sensor lights up if the relation exceeds the set JRA alarm limit.
Setting: Alarm limit 0.0% to 100.0%
Alarm limit: 0.0 = monitoring inactive
Special monitoring functions

Special monitoring can only be switched on and off using Customer Service access rights.
If the special monitoring functions are activated they react as follows:
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
Yarn jumps are registered and counted.
A cut follows a yarn jump.
Cut, textile alarm with SP blocking (3 x JMP / 1 km).
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
USTER QUANTUM 3
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
Drum wraps are registered and counted.
Cut at drum wrap
Espero, Orion, Polar, Smaro and Spero: Winding machine stops without cut.
Effect at danger of drum wrap
Other machines: not available.

X
Cut, textile alarm with SP blocking
Table 11-2
Fig. 11-16
Display of the group setting of the winding machine
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:
Monitoring of the upper thread (U)

If double or even multiple yarns are coming from the cone, the cutter has to be triggered.
U-channel with setting of U%
U-channel for upper threads (U)

The monitoring of the upper thread is only possible on machines on which the upper thread runs
through the clearer measuring field before splicing. The U-channel prevents that an upper thread
(yarn end removed from the cone) is joined as a double thread or as a loop with the yarn which is
drawn off from the bobbin. Therefore, the upper thread is checked when putting it into the measuring
field. With a correct setting of the U-channel, any upper thread which is drawn in as a double or multiple thread, will be cut.
11.4.2 Monitoring of the settings

All the settings should be adjusted according to the produced yarn, especially after putting into operation of the machine. This coordination helps to avoid surprises afterwards.
Monitoring of the settings for the upper yarn detection

With the chosen setting U, a double yarn removed from the cone must always be cut. This can be
checked with a prepared cone with double yarn or with suctioning off an additional yarn from a bobbin. The setting is correct, when all double yarns are cut. Single yarns should not be cut. Incorrect
detection of single yarns as double threads should not be higher than 1 to 2%.
Monitoring of the yarn joint setting

With the chosen setting Jp and the corresponding length a good quality joint should not be cut. The
checking is done best with a double yarn from the cone side. During this procedure, the U-channel
has to be switched off (U = 0%). Therefore, Jp has to be set rather sensitive. It has to be pointed out
that the set length does not have to correspond with the actual yarn joint.
11.4.3 Splice classification

Up until now, visual checks of the splice were carried out in periodic intervals with random samples.
This is also recommended by the machine manufacturers. However, this check is very timeconsuming.
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
Scatter plot with splice classification
11.4.4 Yarn jump monitoring (JPM, JPA)

JPM
A hard yarn fault, like for example attached fiber balls or a yarn loop, can cause a significant increase
of the yarn tension at a deflection point. The subsequent slackening of the yarn can cause the yarn to
jump out of the clearer measuring field. With other words: a hard yarn fault can jump out of the measuring field and thus will not be monitored.
With the yarn jump monitoring function a cut is triggered as soon as the yarn is out of the measuring
field and a 100% monitoring cannot be guaranteed anymore.
JPM-cuts are mainly caused by yarn faults. In principle, JPM-cuts should, therefore, be considered as
yarn fault cuts.
JPM-cuts can also be caused by a very unstable yarn movement.
Our recommendation: Turn on function Yarn jump monitoring.
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
11.4.5 Drum signal monitoring (DSM)

Winding machines with a guide drum signal generate a certain number of pulses per revolution of the
drum. These pulses are used to calculate the yarn speed and the length of yarn faults. Without a
guide drum signal, yarn clearing is not possible on those winding machines.
If no guide drum signal is provided within approx. 5 seconds after the start of the winding position or if
the clearer detects a failure of the guide drum signal, a DSM-cut and an alarm is triggered by the
clearer. This means, that the clearer gets no yarn speed information.
If the DSM monitoring is turned off, the drum signal will not be monitored and the yarn clearing might
not be guaranteed.
Our recommendation: Turn on function Drum signal monitoring DSM.
11.4.6 Drum wrap monitoring (DWM, DWA)

DWM
A drum wrap can occur, when the yarn breaks in the guide drum during traversing. After the break,
the yarn usually stops briefly in the guide drum as well as in the measuring field. A drum wrap occurs
when the yarn is subsequently wound onto the guide drum.
The dynamic yarn detector (DYD) detects the brief stoppage of the yarn. The DYD is switched-off,
which results in a DWM-cut and prevents a drum wrap. Practical experience has shown that this is
mostly the case.
But drum wraps can also happen for other reasons (sticking of the splice to the drum) and therefore,
not all drum wraps can be avoided with this monitoring function.
If the DWM monitoring is turned off, drum wraps cannot be avoided by the clearer.
Some machine manufacturers also offer their own drum wrap monitoring.
Our recommendation: Turn on function Drum wrap monitoring DWM.
Don't cut drum wrap

If the function Don't cut drum wrap is activated (Espero, Orion, Polar, Smaro, Spero), the winding
position will only be stopped, but no cut is triggered. This can avoid free flying yarn pieces.
Our recommendation: Turn on function Don't cut drum wrap.
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.
11.4.7 Cut monitoring CTM

With CTM monitoring, it is checked, if the yarn has been separated after a cut. If the cut fails repeatedly, a CTM alarm is triggered. If the CTM monitoring is turned off, the clearer cuts are not monitored.
Our recommendation: Turn on the function Cut monitoring.
11.4.8 Zero point monitoring ZPM

During splicing of a winding position, the clearer adjusts itself when the measuring field is empty. Deviations from zero are adjusted to zero again. The measuring field must be empty for this procedure. If
this adjustment is carried out while the measuring field is not empty, the zero point would not be set
correctly and wrong measurements could occur.
With the zero point monitoring ZPM turned on, the condition of the measuring field is monitored during
the zero point adjustment. In this case, the zero point adjustment is only carried out with an empty
measuring field.
If the ZPM is turned off, a zero point adjustment is carried out, even if the measuring field is not empty
and also in case of a piece of yarn remaining in the measuring field. If the piece of yarn falls out of the
measuring field during the adjustment cycle, the yarn clearer does not recognize the laid-in upper
yarn. This can have the effect, that:
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.
Our recommendation: Turn on the function Zero point monitoring ZPM.
USTER QUANTUM 3
11.17
11
11.18
USTER QUANTUM 3
Clearing of slub yarns
12.
Clearing of special yarns
12.1
Introduction to fancy yarns
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
Clearing of fancy yarns
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
Mock spiral, mouline, jaspe
Gimp
Frise, caterpillar, onde
Slub
Ground slub, injected slub, injected flame (also called tear- off flame)
Knop
Knot, nep, noppe, button, reverse caterpillar, flake
Loop
Boucle, frotte, pong, mock-spun chenille
Cover
Twisted flame
Chenille
Woven chenille, plied chenille
Snarl
Table 12-1 Various fancy yarns [1]
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12.1
12
Fig. 12-1
Examples of effect twist fancy yarns [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
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Yarn (produced) effects
12
Spun yarn effects
Regular effects
Controlled discontinuous effect
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.
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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
Any length over

2 meters
Multitwist
variable
variable
constant
any
Table 12-3 Definition of different slub yarn types
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
Slub yarn with short slubs on a blackboard
Setting of a clearing limits for slub yarns

With the USTER QUANTUM 3, there is a special setting for slub yarns. For this, we can use the radio buttons to switch from NSL thick places to Slub Yarn settings window. The aim of this feature is to
define the clearing limit to prevent the clearing of desired thick places in slub yarn. The events in the
defined slub area should not be cut because this is a characteristic of the yarn. In order to clear slubs,
instead of standard setting points P, we have the special setting points K1 to K3 to zone out areas
where slubs should not be cut. For example: Set point K1 = 700% / from 10.0 cm to 25.0 cm. This
means the slubs between 10.0 and 25.0 cm are not cut.
12.4
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12
It is possible to assign up to 3 K areas where slubs should not be cut Fig. 12-3.
Fig. 12-3
Slub yarn setting. No clearer cuts up to +700% from 10 to 25 cm.
Characteristic yarn faults in slub yarns

The clearing of slub yarns should achieve the following: Specifically generated "thick places" should
remain in the yarn, disturbing yarn faults have to be cleared.
Slub yarns consist of at least 2 single yarns, i.e. if one of them is missing, the yarn clearer has to detect this. The existence of each single yarn has to be monitored.
Faults in the single yarns have to be eliminated, in order to avoid any unevenness in woven or knitted
fabric.
12.4
Clearing of yarns with nep or loop effects
Fundamentally, it can be said:
The desired effect has to be monitored. If the effect is missing, a cut has to follow.
Each single yarn of the ply yarn has to be monitored.
Possible yarn faults in the single yarn must be monitored.
Fig. 12-4
Yarn fault in a boucl yarn
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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.
Characteristic yarn faults in melange yarns

For melange yarns it is of particular importance that the blending effect, i.e. the blend of multicolored
fibers is as regular as possible. If too many fibers of one component are missing, it is possible that
stripes of a particular color occur in the end product.
Fig. 12-5
Melange yarn / Blending problems /

Blend of black and white fibers 100% cotton, Ne 30 (20 tex), OE rotor
Fig. 12-6
Melange yarn / Blending problems
Choice of the measuring head

It is not possible to monitor uneven color effects with a capacitive measuring head. The increase or
decrease of one fiber component is less than the normal mass unevenness of a yarn.
With the USTER QUANTUM 3 iMH-O30, it is possible to monitor the proportion of blending.
For the clearing of long color deviations, it is necessary to set the CC-channel accordingly. The defined length must correlate with the expected fault length. If necessary, the set length must be shortened and the diameter must be increased in 2%-steps.
12.6
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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%.
Clearing of core yarns (CY)

Core yarn monitoring; detects the break of the core while yarn is running. A cut takes place if the cover thread is missing and at yarn break. The setting parameters are:
Tolerated decrease in %.
This setting is only active when the yarn type is core yarn.
Sensitivity: 0% = Clearing channel inactive
Fig. 12-7
Core yarn setting (CY)
A missing core can only be detected if the mass of the core is at least 13% of the entire yarn mass.
Clearing of a yarn with missing cover

Besides normal thick places, a missing cover is also disturbing. Therefore, a partly or completely
missing cover must be monitored.
In case of sewing threads, a classification of short neps is required. Neps are considered as disturbing events if they are occurring in high numbers. The frequency of such neps is an indicator for the
running behavior of the yarn on the sewing machine.
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12.7
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12.8
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The first hour at the new clearer system
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
Short description of the settings
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.
Create and start an article

Whenever the article on the winding machine has to be changed, the designation of the article has to
be made first. Page 13.3 shows what kind of steps have to be taken for a new article.
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.
Setting of Periodic Faults (PF)

Page 13.5 shows the settings for periodic faults.
Setting a smart clearing limit for dark foreign matter (FD)

Page 13.6 shows the setting of the optimum clearing curve for the elimination of foreign matter.
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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.
Setting a smart clearing limit for Polypropylene Clearing (PP)

Page 13.8 shows the setting of the clearing curve for polypropylene clearing. Polypropylene detection
is significantly more difficult than the detection of colored fibers in white yarns because the color of
polypropylene hardly differs from the color of yarn.
Setting a clearing limit for count deviation clearing (C)

Page 13.9 shows the clearing of count variations in the length category 2 to 12 m. The count variations particularly serve for the recognition of wrong bobbins.
Setting a smart clearing limit for count monitoring clearing (CC)

Page 13.10 shows the steps to be taken to monitor the count deviation of the yarn during the entire
operation. The settings are also made between 2 and 12 m.
Setting a clearing limit for Splice Clearing (Jm /Jp)

Page 13.11 demonstrates how the clearing limits can be set for splices. If bad or faulty splice is located above the splice clearing limit, the splice is eliminated and replaced by a better splice.
Setting of Q Parameters: Yarn Evenness (CV)

The evenness CVm belongs to the most important quality characteristics of yarns. The reference
length is selectable. Alarm limits are available for every single measurement as well as for the group
average / mean value. The procedure is shown on page 13.12.
Setting of Q Parameters: Hairiness (H)

Page 13.13 shows the settings for hairiness. The reference length is selectable. Alarm limits are
available for every single measurement as well as for the group average / mean value.
Setting of Q Parameters: Imperfections (IP)

Page 13.14 demonstrates the steps to be taken to set the sensitivity and the alarm limits for frequent
thick places, thin places and neps. Outlier bobbins can also be detected and eliminated.
Setting of Q Parameters: Class Alarm

Page 13.15 explains the settings for class alarm. It is an option to set alarm limits for up to 5 individual
class of the Classimat matrix.
Setting of Q Parameters: Tailored Classes

Page 13.16 shows how mill-specific classes can be selected, if required.
13.2
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13.3
13
13.4
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13.5
13
13.6
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13.7
13
13.8
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13.9
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13.10
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13.11
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13.12
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13.13
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13.14
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13.15
13
13.16
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Frequently asked questions
14
14
This paper was written to answer the questions which are asked frequently by our customers.
14.1
14.1.1
Product related questions

What type of sensing principles does USTER QUANTUM 3 offer?
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:
Capacitive C15, C20
Optical O30
Foreign matter C15 F30, C20 F30 or O30 F30 *
*PP is an option to the C15F30, C20F30 and O30F30 measuring head see also 15-2.
14.1.2
How does the USTER QUANTUM 3 differ from competing products?
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
What are the main new functions of the USTER QUANTUM 3?
USTER QUANTUM 3 offers a host of new innovative features such as:

Smart clearing
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
Cut forecast for the selected clearing limit
Smart count clearing
Detection and elimination of bobbins with wrong counts
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
Detection of periodic defects (spectrogram peaks) of multiple wavelengths

Advanced splice clearing
Synchronized to clearing limits to ensure safe quality
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.
Foreign Matter clearing
Detection of all colors of foreign fibers using multiple light sources
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
Designation of the thick and thin places classes
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
Designation of the foreign fiber and vegetable classes
Even small Polypropylene defects

As always the quality data is on the same basis as the established Uster laboratory instruments
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
What is new with the USTER QUANTUM 3 optical basic clearer?
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
What is the difference to UQC2 Vegetable Filter?
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
What is the advantage of the USTER QUANTUM 3 for core yarns?
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
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14.1.9
14
What is the benefit of slub yarn setting in USTER QUANTUM 3?
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.
14.1.10 How is the PP performance of the new clearer?

The USTER QUANTUM 3 PP clearing is based on the newest sensor technology.
The new PP sensor has high detection efficiency with a high cut accuracy resulting in reduction of
disturbing PP in the fabric like never before.
The illustration by means of the scatter plot enables to choose or fine tune the clearing limits in an
easy and reliable way.
14.1.11 How are the repair costs of USTER QUANTUM 3?

USTER products always offer high reliability and accuracy. The USTER QUANTUM 3 also delivers
on this promise.
Building on the proven USTER QUANTUM 2, the USTER QUANTUM 3 is a tough, robust clearer
which will need less maintenance and repairs and therefore lower running costs.
14.1.12 What are the advantages from a maintenance point of view?

The USTER QUANTUM 3 has a mechanical design that reduces maintenance. The foreign matter
sensor is taller and wider with stable yarn path. This result in less dirt deposits and therefore needs
far lower cleaning than conventional clearers. This has been proven in extensive tests in challenging
environments.
The electronic assembly is better shielded to prevent dust and dirt and is also better decompled from
the vibrations of the cutter. This ensures higher performance stability and the enhanced lifecycle.
As a result of the above, users can expect a long lasting, less maintenance demanding clearer with
solid performance.
14.1.13 Can the USTER QUANTUM 3 is installed be winders of previous generations?

USTER QUANTUM 3 with its versatile design can also be used for retrofits on older automatic winders. Please refer to the Technical Data Sheet on www.uster.com to see the list of winder models. Our
sales organization will be glad to assist you in all respects.
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14.5
14
14.1.14 Why does the USTER QUANTUM 3 have a bigger housing?

USTER QUANTUM 3 is USTERs biggest clearer to date - quite simply to fit all new robust technology. Tough on the outside, its completely newly designed to stand up to the most demanding mill environments and provide a long life. Like a better sealed clearer core which keeps out dirt and dust, reinforced sensors, which can cope with vibration, thermal stability etc.
The new air blowing arrangements reduces dirt build-up of the sensor from both the yarn and the air
supply. These QUANTUM 3s innovations will help the clearer to work better, last longer and need
less cleaning and maintenance.
Another major reason is the new sensor design. The capacitive sensor; optical sensor and the foreign
matter sensor all occupy more space for better performance. The foreign matter sensor for example is
higher and wider than before, which reduces dirt deposits and therefore needs less cleaning and
maintenance.
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
Application related questions

What kind of yarn clearer do I need for my application?
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
How is it possible to simplify the definition of clearing limits?
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
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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
What is the best basic setting for my yarn?
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).
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14.7
14
14.2.7
What is the USTER QUANTUM 3 advantage with respect to compact yarns?
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
When should I use the vegetable clearing?
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
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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.
14.2.12 How can one set up the splice clearing curve?

With the USTER QUANTUM 3 splice clearing also has made a substantial jump. A smart possibility
offered by the system is to synchronize the splice settings to the NSL T settings to avoid bad splices
being passed
The splice clearing curve could be placed ideally as same as the NSLT clearing limits.
For highest quality requirements the Jp, Jm setting can even be set up to -5 to -10% below the NSLT
clearing limit.
If this will results in too many JP or Jm cuts then the rogue splicers should be identified and fixed.
USTER QUANTUM 3
14.9
14
14.2.13 How can one find/identify rogue splicers?
Use JR Splice failure ratio (miscellaneous, JR splice failure ratio)
Use JRA splice failure ratio alarm (group setting)
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
Designation of the thick and thin places classes
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.
14.2.17 Can I use the QUANTUM 3 for wet splicer applications?

The USTER QUANTUM 3 optical clearer can be used with wet splicer without any restrictions.
The capacitive clearer can be used with restrictions on the amount of water sprayed. Please contact
USTER for support.
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.
14.2.18 Is it possible to classify foreign fibers?

The USTER QUANTUM 3 classifies foreign fibers and vegetables in the USTER FOREIGN CLASS
matrix. The faults are classified according to the reflection (%) and length (mm). The system also illustrates the frequency of foreign fibers and vegetables as dense areas to facilitate easy settings.
The system provides numeric classification and the scatter plot of foreign fibers and vegetables including the dense area display.
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
USTER QUANTUM 3
14
14.2.20 Can we compare the classification of C15 on C20 in USTER QUANTUM 3

The USTER QUANTUM 3 new capacitive sensor has shorter guarded measuring fields (4mm). As a
result of the new technology, the classification of C15 and C20 is comparable.
This means the clearing limits can be similar between these clearer types and the cuts, clearing performance for C15 or C20 is comparable. Users can now choose the most appropriate iMH type for
their application.
14.2.21 Is the USTER QUANTUM 3 classification comparable to the USTER STATISTICS?

The Quality Data such as the coefficient of variation of the yarn evenness, the thick places, thin places, classification results and hairiness can be compared with the USTER STATISTICS. It has to be
taken into consideration, however, that the environmental conditions are not the same on the machine
and in the laboratory, and, therefore, we have to compare the figures with more tolerance than between two laboratory systems.
USTER QUANTUM 3
14.13
14
14.14
USTER QUANTUM 3
Technical specifications
15
15.1
Basics of USTER QUANTUM 3
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.
15.1.2 Scope of application

Yarn types:
For all spun yarns consisting of natural fibers, blended fibers, synthetic fibers and plyed yarns.
Languages:
GB, CN, TR, VN, DE, FR, IT, ES, PT
Count range:
Nec 3 to Nec 200 / Nm 5 to Nm 340 / 2.9 to 200 tex
Maximum speed:
2200 m/min
General Ambient conditions:
- Temperature range +5 to 50C / 41 to 122F

- Humidity up to 95%, not condensing
15.1.3 Scope of supply

iMH for each position, Central Clearing Unit 6 (CCU6), Documentation, Tools, Yarn Boards, Yarn
Grades
USTER QUANTUM 3
15.1
15
15.1.4 Miscellaneous
Printer:
USB Printout or via an optional portable printer
Access Rights:
Controlled through programmable passwords
Unit system:
Nec, New, Nm, Tex
15.2
Structure of the USTER QUANTUM 3
15.2.1 Features of USTER QUANTUM 3 and options

Table 15-1 shows the individual features of the options.
OPTIONS
FEATURES
COMMENTS
Yarn Body (N, S, L, T, CC)
Visualization of the yarn characteristics
Smart limits (N, S, L, T, CC)
A proposed starting point for clearing limits
Scatter plot (N, S, L, T, C, CC, J)
Visualization of the thick and thin places, count deviations

and splices.
N, S, L, T
Elimination of the disturbing thick and thin places
C, CC
Count deviation clearing and monitoring
Jp, Jm
Splice Clearing
Cut forecast
A forecast of cut numbers per 100 km
Technical alarms
Alert for technical problems
Textile alarms
Alert for textile problems
Dense Area (FD, FL, VEG)
Identification of range where foreign fibers are located
Smart limit (FD)
A proposed starting point for foreign fiber clearing limits
Scatter plot (FD, FL)
Visualization of dark and light foreign fibers
Dark foreign matter (FD)

Light foreign matter (FL)
Elimination of dark and light foreign fibers
On-line foreign matter classification
Classification of foreign fibers
Identification of vegetables
Separation of vegetable matter
On-line vegetable classification
Classification of vegetable matter
(Option)
Smart limit (PP)
A proposed starting point for polypropylene clearing limit
Scatter plot (PP)
Visualization of polypropylene fibers
Q-Data (Option)
Evenness (CV)
Determination of the yarn evenness
Imperfections
Determination of the frequent thick places, thin places and

neps
Basic on-line classification (NSLT, FD, J and

VEG)
Classification of disturbing thick and thin places, foreign

fibers, splices and vegetables
Class alarms
Triggering of alarm if the number of disturbing faults has

exceed the selected number of faults
Periodic Faults (PF)
Detection of periodic faults
Basic clearing
Foreign
matter
Vegetable
Clearing
(Option)
15.2
USTER QUANTUM 3
15
OPTIONS
Hairiness
(Option)
Expert (Option)
Advanced
Classification (Option)
Lab On-line
(Option)
Table 15-1
FEATURES
COMMENTS
Absolute hairiness measurement
Determination of the hairiness value
Exception spindle detection
Recognition of spindles with excessive hairiness
Expert
Access to the data output for Expert System and centralized data collection and reporting
Extended Classes
Tailored classes
Classes can be selected by customers
Software pack
Software pack consists of Hairiness, Advanced Classification and Expert
Features of Basic Clearing and options
15.2.2 Features versus measuring head types

Table 15-2 below describes what type of USTER QUANTUM 3 sensor for each measuring head is
appropriate for which kind of application.
FEATURES
MEASURING HEAD TYPES
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
ADVANCED CLASSIFICATION (Option)
LAB ONLINE (Option)
---
---
---
Table 15-2
The USTER QUANTUM 3 sensors and options
USTER QUANTUM 3
15.3
15
Key:
X
This feature is included in this version of the sensor
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
---
Not available with this iMH type
15.3
Comparison, capacitive versus optical measuring principle for basic clearing
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
A capacitive measuring signal is proportional to

the cross-section of a yarn
An optical measuring system is proportional to the

diameter of a yarn
Sensitivity
A thick place with 3 times more fibers in the

cross-section than average produces a signal
of +200%
A thick place with 3 times more fibers in the crosssection than average produces a signal of +73%
(Exception: N, S faults)
Application
range
For most of the yarns the capacitive principle

can be utilized.
For all the yarns the optical principle can be utilized.
Contamination
The capacitive system needs less cleaning of

the measuring zone. Particularly useful in dirty
environments
The optical system needs more cleaning of the

measuring zone
Exception 1:
Conductive
fibers
The capacitive system is affected by conductive fibers and should not be utilized for such
yarns
The optical system is not affected by conductive

fibers
Exception 2:
Dyed yarn
The capacitive system is not affected by color

variations
The optical system is affected by color variations
Exception 3:
Wet splicing
It is recommended to minimize the amount of

water used for splicing to protect the clearer
and the machine.
The optical system is recommended
Exception 4:
Wet spun linen
Not recommended
The optical system is recommended
Table 15-3
15.4
Comparison capacitive versus optical measuring principle for basic clearing
USTER QUANTUM 3
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
Oerlikon Schlafhorst Autoconer AC5 and AC X5
Oerlikon Schlafhorst Autoconer 338
Savio Orion
Savio Espero
Savio Polar
Savio Orion
Savio
Oerlikon Schlafhorst Autoconer AC5 and AC X5
Savio Polar
Qingdao
Qingdao Smaro
Qingdao Smaro
Table 15-4
15.5
Count range of the USTER QUANTUM 3
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
Architecture, sensor principles and configuration
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.
Sensor prinMass variation

ciples for
Diameter variation
basic clearing
Length of measuring zone:

Mass variation:
4 mm
Diameter variation: 3 mm
Physical principles:
Mass variation:
capacitive
Diameter variation: optical
Sensor principle for foreign fiber

detection and
monitoring of
the hairiness
Length of measuring
zone: 2 mm
Physical principle:
Measurement of phase shift

of 2 different materials
Length measurement of polypropylene fibers is possible.
Reflectance
Sensor for
Phase angle
polypropylene
detection
Sensor configurations
Basic clearing: Capacitive or optical
optical
Physical principle: capacitive

Same measuring head dimensions for all sensor
configurations
Basic and foreign

fiber clearing:
Capacitive and optical;
Optical and optical
Table 15-5
15.6
USTER QUANTUM 3
15
15.7
Elimination of disturbing yarn faults
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
Long thick- and

thin place
(count variation
during winding
process)
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
The clearing curve can be

optimized by means of 8 setting
points for NSL faults.
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)
The clearing curve can be

optimized by means of 8 setting
points for T faults.
2 m (default)
Basic
Monitoring of long thin- and

thick places
CCm 1
0*/-1...- 80%
2 m (default)
CCm 2
0*/-1...- 80%
12 m (default)
PF
0*/50...100%
---
Furthermore, setting of the

number of periods: 5 500
FD
0*/3...100%
0...10 cm
There are 8 setting points each

for the FD channel
There are 4 different modes:

Close, medium, open and
as FD
VEG
Close, medium, open

and as FD
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

for Jp
Jm
0*/-1-100%
010 cm
Basic

for Jm
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
Available with both C15F30PP

and C20F30PP clearers
Basic
Table 15-6
Abbreviation:
Q = Q-Data
F = Foreign fibers
USTER QUANTUM 3
PP = Polypropylene
0* = Inactive (off)
15.7
15
15.8
Supervision of the machine operations
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
All winding machine types if

needed
Table 15-7
0* = Inactive (off)
15.8
USTER QUANTUM 3
15
15.9
Determination of quality characteristics
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%
No substantial variation when changing the evaluation length.

Measurement can be started at bobbin change or can be done continuously.
Coefficient of
variation per
position
CV-SP
50 ... 10'000 m,
0*/1 99%
No substantial variation when changing the evaluation length.
Imperfections:
IPI
Evaluation length:
502000m
Alarm limit: 0*/164000
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
Thick place classes:

30 45%, 45 75%,
75 100%, 100 150%,
150 250%, 250 400%,
> 400%
Imperfections are always displayed

per 1000 m (reference length)
Total number of yarn faults per class

(absolute) and relative per 100 km
30 thick place classes and 15 thin
place classes.
Q, A
Thin place classes: H0,

H1, H2, I0, I1, I2, TB1,
TB2, TC1, TC2, TD2,
TD1, TD:
-20..-30%, -30...-45%,
< -45%
Periodic faults
Number of disturbing thick and
thin places
Wrong count
USTER QUANTUM 3
PF
As defined in chapter 15.7
Total number of yarn faults per class

(absolute) and relative per 100 km
N, S, L, T
Basic
Total number of eliminated yarn

faults per class (absolute) and relative per 100 km
Cp, Cm
Basic

faults(absolute) and relative per 100
km
15.9
15
Quality
characteristics
Abbreviation
Technical
specifications
Options
needed
Comment
Count deviation
and monitoring of
uneven long thick
and thin places
CCp, CCm

faults (absolute) and relative per 100
km
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
Total number of foreign fibers per

class (absolute) and relative per
100 km
32 displayed foreign fiber classes.
Reflectance classes:
5-7%, 7 10%, 10 20%,
20 30%, 30 100%
1 table for FD,
Foreign fibers,
grey or colored
yarns
FD

faults per class (absolute) and relative per 100 km
Polypropylene
fibers
PP
PP
Available with both C15F30PP and

C20F30PP clearers
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
Total number of vegetable matter per

class (absolute) and relative per 100
km
32 displayed vegetable matter classes.
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.
Deviation in length and percent from

the nominal value are displayed.
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
15.10 Cut alarms, Quality alarms, Special Counters and Logbook

Choices
Subject
Abbreviation
Settings
Reference
length
Options Comment
needed
Yarn fault
alarms
Short thick places
NSA
0*/1...99
1...999 km
Basic
Long thick places
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
Count deviation and

uneven, long thick and
thin places
CCA
1...999 km
Basic
Foreign matter
FA
1...999 km
PPA
1...999 km
PP
iMH C15F30 and C20F30

with option PP
Periodic faults
PFA
1...999 km
Monitoring of the fault frequency
Splice failure ratio

alarm
JRA
0*/1100%
---
Basic
Monitoring of the frequency
Coefficient of variation, CV-MV

mean of entire machine or article
upper:
0*/0.1...99%
0,05...10 km
Absolute monitoring of the

CV-MV; upper and lower
limit.
Coefficient of variation
per position
upper:
0*/1...99%
0,05...10 km
Relative deviation of the

CV-MV value
0,05...10 km
Absolute monitoring of the

H-MV value; upper and
lower limit.
0,05...10 km
Absolute deviation of the HMV value
(ALARM)
QRegistration
Q-Blocking
Q-Cut (Ejection)
Q-Blocking /
Sucking
Monitoring of the fault frequency
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
Hairiness per winding

position
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
5 individual classes for

alarm monitoring can be
selected
Frequent neps
IP
0*/1...64000
0.05...10 km
Frequent thick places
IP
0*/1...64000
0.05...10 km
Frequent thin places
IP
0*/1...64000
0.05...10 km
Tailored classes (NSL) tNSL
0*/5900%
0.1200 cm
Tailored classes (T)
tT
0*/-5-100%
0.1200 cm
Tailored classes (FD)
tFD
0*/5100%
0.110 cm
Tailored classes (FL)
tFL
0*/5100%
0.110 cm
Upper yarn cuts
0*/10...200%
Machine-associated
---
Basic
USTER QUANTUM 3
---
Basic
15.11
15
Choices
Subject
Abbreviation
Settings
Reference
length
Options Comment
needed
additional cuts
Logbook
Yarn jump monitoring /

registration/ alarm
JPM /
JPM reg --/ JPA
---
Basic
Drum wrap monitoring

/ registration/ alarm
DWM
DWM
reg
/DWA
---
---
Basic
Drum signal monitoring
DSM
---
---
Basic
Special cuts
SPC
---
---
Basic
Recording of all
changes and alarms
Logbook ---
---
Basic
Monitoring of the logbook

entries
Table 15-9
Abbreviations:
Q
= Q-Data
= Foreign fibers
= Hairiness
PP = Polypropylene
A
= Advanced Classification
0* = Inactive (off)
15.12
USTER QUANTUM 3
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
Produced yarn length
Basic
Settings
Setting of the clearing- and

alarm parameters
---
---
Basic
Yarn
Faults
Number of all yarn faults YF

absolute
---
Basic
Number of all yarn faults YF /

100 km
Basic
Number of all yarn joints YJ /

absolute
---
Basic
Number of all yarn joints YF /

100 km
Basic
Number of N, S, L, T, Cp, Cm,

CCp, CCm absolute
---
Basic
Number of N, S, L, T, Cp, Cm,

CCp, CCm / 100 km
Basic
Periodic Faults absolute
---
Periodic Faults / 100 km
Foreign fibers, grey or colored

yarns, FL, FD absolute
---
Foreign fibers, grey or colored

yarns, FL, FD / 100 km
Polypropylene fibers PP, absolute
---
PP
Polypropylene fibers PP /
100 km
PP
Faulty yarn joint Jp, Jm absolute
---
Basic
Faulty yarn joint Jp, Jm /

100 km
Basic
Cuts U, JPM, SPC, DSM,

DWM absolute
---
Basic
Cuts U, JPM, SPC, DSM,

DWM / 100 km
Basic
Yarn fault alarms NS, L, T, F,

C, CC absolute
---
Basic
Yarn fault alarms NS, LT, F, C,

CC /100km
Basic
Periodic Faults alarm PF absolute
---
Periodic Faults alarm PF / 100

km
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
Per position
Q Alarms
Printout
Display
Printout
Necessary
options
Number of CV alarms CVp,

CVm absolute
---
Number of CV alarms CVp,

CVm / 100km
Number of Hairiness alarms

Hp, Hm absolute
---
Number of Hairiness alarms

Hp, Hm / 100km
Number of Class-alarms absolute
---
Number of Class-alarms / 100

km
Number of Imperfection alarms

absolute
---
Number of Imperfection alarms

/ 100 km
---
---
Basic
Exceptions: F, VEG, PP
---
---
Exceptions: CV, IP, Class, (H)
---
---
Coefficient of variation per

group CV-MV
---
---
Coefficient of variation per

position CV-SP
---
---
Mean imperfection counts 12 in

different classes / 1 km
Classification of NSLT faults /

100 km, absolute
---
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
Hairiness, mean value of the

group H-MV
---
---
Last value of the hairiness per

winding position H-SP
---
---
Yarn faults (N, S, L, T, C/CC,

F, VEG, PP, PF)
**
**
**
**
Basic, F, PP
Textile alarms (NS, L, T, C/CC,

F, Q, PF) Blockings/Cuts/Registrations)
**
**
**
**
Other
**
**
**
**
Feature
Exceptions Exceptions: yarn faults, textile

alarms, J, JR, yarn length
SP
Q Data
Event
reports
Per group
Display
Groups
Comment
Yarn faults are

also displayed
Basic, F, Q, showing size,
H, A
intensity and
classification.
Basic
Table 15-10
15.14
USTER QUANTUM 3
15
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
15.12 Clearing of various yarn types
Cotton, carded, combed, compact ring
X*
Blended, short staple
Synthetics, short staple,100%
Cellulosics,100%
Woolen
Worsted
Blended, long staple
Synthetics, long staple,100%
Flax,linen, hemp
Wet spun linen
Spun Silk
Technical yarns, non-conductive
Technical yarns, conductive
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
15.13 Recommendations how to use clearers

15.13.1
Sensor systems versus end use of yarn
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
***
Recommended. Limitations for some applications.
**
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
---
Should not be used for this application
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
*****
*****
*****
Same color / 2 ply
*****
*****
***
Different colors / 2
ply
*****
***
---
3 ply and more
*****
****
---
*****
*****
***
*****
*****
***
Grey
*****
*****
***
Dyed
*****
***
***
All yarn
counts
100% Synthetic yarns

Worsted
yarns
worsted/
synthetics
blended
yarns
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
Type of yarn
Melange
(Blended
yarns with
long staple
fibers of different colors)
Count
range
Ne
All yarn
counts
and
blends
End use
Blending of colored fibers at

drawframe
Blending of colored fibers at

spinning machine
Sewing threads
Core yarns
All yarn
counts
*****
IMH-O
*****
IMH with F
Recommendation for
sales engineers
****
Short yarn defects are

mostly of the same color
and appear as small
spots
The mass deviation of
the missing colored fibers
are very small but the
visual impact can be
significant
**
***
****
*****
*****
*****
Yarns for industrial

use and with a
core of more than
14 % of the total
mass
*****
---
***
With Lycra as core
*****
***
*****
****
****
***
Challenges depend on
the end use
***
Mostly the missing slubs

are a problem and, therefore, the visual appearance is most important.
---
Capacitive sensors are

unable to measure metallic fibers or highly conductive fibers correctly.
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
*****
---
*****
****
The biggest problem is

the missing core since
the yarn does not break.
Such defects can only be
detected with iMH-C.
Linen, flax,
hemp yarns
***
*****
---
Should customer already

successfully use C-type
clearers, iMH-C can be
offered
Linen
(wet spun)
---
*****
----
Use only optical clearer

for wet spun yarns
10
Spun silk
****
****
*****
11
Filament
yarns
***
***
---
Ask Uster specialists

before offering and send
samples for investigation
Table 15-12
USTER QUANTUM 3
15.17
15
15.13.2
Poor environmental conditions
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
Recommendation for sales engineers
****
*****
*****
When the winding room is separated from the

spinning department the air humidity can fluctuate rapidly
Water spraying only
**
*****
*****
The moisture of the yarn and the humidity can

fluctuate rapidly
Floor watering only
***
*****
*****
The humidity can fluctuate rapidly
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.
16.1.1 Standard settings for the capacitive clearer Capacitive Default
Fig. 16-1
Standard settings
USTER QUANTUM 3
16.1
16
Appendix
16.1.2 Standard settings for the optical clearer Optical Default

The following standard settings should assist when setting clearer for short staple yarns and their
blends.
Fig. 16-2
16.2
Standard settings
USTER QUANTUM 3
Appendix
16.2
16
Abbreviations
Machine-related additional cut
A0...A4
Classimat classes
ADMV
Analog Digital Mean Value
B0...B4
Classimat classes
BC
Board Computer
BI
Built in
Yarn Count deviation during start-up (wrong bobbin)
C0...C4
Classimat classes
CA
Yarn Count Alarm during start-up
CC
Yarn count fault during operation (Continuous Count)
CCA
Yarn count alarm during operation (Continuous Count Alarm)
CCm
(CC-) Lower tolerance limit for yarn count faults during operation
CCp
(CC+) Upper tolerance limit for yarn count deviations during operation
CCp1..2
Setting point for CC
CCU 6
Central Clearing Unit 6
Cm
(C-) Lower tolerance limit for yarn count faults during start-up
(m = minus)
CMT
Yarn fault classification
CMTA
(4 cm fault classification Alarm) named as Class Alarm
Cp
(C+) Upper tolerance limit for yarn count faults during start-up
(p = plus)
CSA
Clearer Spindle Adapter (interface to machine)
CSG
Communication central clearing unit (iMH bus connection)
CTM
Cut Monitoring
CV
Coefficient of Variation of yarn evenness
CVA
Coefficient of Variation of yarn evenness Alarm
CV-MVAm
CV Mean Value Alarm -
CV_MVAp
CV Mean Value Alarm +
CY
Core Yarn
D0...D4
Classimat classes
DEF
Defined (Status of the article)
DSM
Drum Signal Monitoring
DWA
Drum Wrap Alarm
DWM
Drum Wrap Monitoring
DYD
Dynamic Yarn Detector
USTER QUANTUM 3
16.3
16
Appendix
Classimat class
EHR
Machine (unit) computer (Schlafhorst)
Foreign matter
F, P21 .. 22
Classimat classes
FA
Foreign matter Alarm
FD
Foreign matter Dark (dark fiber in light yarn)
FD1... FD8
Setting Points for Foreign matter Dark (dark fiber in light yarn)
FL
Foreign matter Light (light fiber in dark yarn)
FL1... FL8
Setting Points for Foreign matter Light (light fiber in dark yarn)
FMA
Foreign matter sensor Monitor Alarm
G, GP21 .. 22
Classimat classes
GR
Group
GUI
Graphic user interface
Hairiness
HA
Hairiness Alarm
H-MVAm
H Mean Value Alarm -
H-MVAp
H Mean Value Alarm +
H0...H2
Classimat classes
I0...I2
Classimat classes
iCSA
Intelligent Clearer Spindle Adapter
iMH
Intelligent Measuring Head
iMH-C
Measuring head, Capacitive
iMH-F
Measuring head with Foreign matter detection
iMH-O
Measuring head, Optical
INF
Informator (Schlafhorst)
IPI
Imperfections
(Splice Clearing), Joint (yarn splice/knot/piecing/connection)
Jm
Lower tolerance limit for yarn joints
Jm1... Jm 8
Setting Points for Lower tolerance limit for yarn joints
Jp
Upper tolerance limit for yarn joints
Jp1... Jp 8
Setting Points for Lower tolerance limit for yarn joints
JPA
Jump Alarm (yarn)
JPM
Jump Monitoring (yarn)
JR
Splice failure Rate
JRA
Splice failure Rate Alarm
K1...K3
Slub yarn auxiliary setting point
16.4
USTER QUANTUM 3
Appendix
Long thick place 8 cm
LA
Long thick place Alarm
LED
Light Emitting Diode
...m
Minus
MA
Machine
MMI
Man Machine Interface (keyboard, display, printer)
MV
Mean Value
Very short thick places (N) < 1 cm
NS
Very short thick places (N) and Short thick places
NSA
Very short thick places (N)and Short thick places Alarm
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
Periodic yarn Fault
PFA
Periodic yarn Fault Alarm
PP
Polypropylene clearing
POK
Product Option Key
PPA
Polypropylene Alarm
PP1... PP 8
Setting Points for Polypropylene clearing
PROD
Production (State of the article)
Q-Data
Quality data
Short Thick place 1 cm, < 8 cm
SEED
Seed coat fragments
SP
Spindle/Spinning Position/Winding position
SPC
Special cut
SP-CTR
Spindle controller (Savio)
STAT
Status
SW
Software
SYD
Static Yarn Detector
Thin place
T1... T 8
Setting Points for Thin places
TA
Thin place Alarm
TB12
Classimat classes
TC12
Classimat classes
TD02
Classimat classes
USTER QUANTUM 3
16.5
16
Appendix
TM
Top Mounted
tNSL
tailored class for NSL
tFD
tailored class for FD
tFL
tailored class for FL
tT
tailored class for T
Upper Yarn
UQC
USTER QUANTUM 3
VEG
Vegetable matter clearing
YA
Yarn fault Alarm
YB
Natural Yarn Breaks
YD
Yarn Detector
YF
Yarn Fault
YJ
Yarn Joint (Splice)
ZPM
Zero Point Monitoring
Nec
English cotton count
Nm
Metric cotton count
tex
Metric cotton count (SI unit)
16.6
USTER QUANTUM 3
16
Appendix
16.3
Explanation of terms
Advanced classification
Article
Article change
Board computer
Bobbin
C-channel
Clearer
The option which includes extended classes and tailored classes.

The article is an identification of the yarn. It is identified by: Article number,
article name and yarn count. From the point of view of the yarn clearer
manufacturer, the article is also defined by the combination of all clearing
settings.
Operation-specific function, which involves one or several of the following
items:
- delete the collected article data; set the counters to zero
- adjust the basic sensitivity to the new yarn of the group
- enter the new settings in the USTER QUANTUM 3.
Computer of the winding machine.
Type of yarn package used in ring spinning.
Fault channel for the detection of yarn count deviation.
Sensor and evaluation electronics of a winding position.
Clearer cut
Cutting of the running yarn to eliminate a disturbing yarn fault or a disturbing foreign fiber.
Clearer cut
blocking
A signal generated by the winder, which prevents a clearer cut, e.g.:

- during the splicing/knotting cycle,
- when the cone is full and being changed.
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
Representation of the yarn faults in the 23 fault classes of the USTER

CLASSIMAT system.
Cylindrical or conical yarn package produced at each winding position of a
winding machine.
Central Clearing
unit
Component of the yarn clearing installation. Some functions:

- centralized operation of the installation
- data exchange with the iMHs
- output of information and results by display and USB-connection
Cross-sectional
deviation
Deviation of the yarn cross-section from the mean yarn value.
Cut forecast
USTER QUANTUM 3
A forecast of the number of cuts per 100 km.
16.7
16
Appendix
Dense Area
Diameter deviation
Display
Double thread
Extended classes
Evaluation unit
Identification of range where foreign fibers are located.

Deviation of the yarn diameter from the mean yarn diameter.
Display panel at the USTER QUANTUM 3 central clearing unit. Shows the
dialog between the user and the operating program.
Two single threads or a faulty yarn spun from two rovings with approximately double the cross-section of the single thread.
-
Fault channel
Group
Guide drum signal
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
On a winding machine, an already existing clearer installation is exchanged

by a new USTER QUANTUM 3 installation.
Scatter plot
Graphic representation of the detected events within a classification matrix.

One event = 1 point.
S-channel
Fault channel for the detection of short thick places.
Sensitivity
Set %-value for the determination of the clearing limit.
Smart limits
Software pack
Software release
Spinning cop
Splice
Splice check
T-channel
Tailored classes
Thick place, long
Thick place, short
A proposed starting point for clearing limits.

A package consists of various software parts (see also Software release).
Released USTER QUANTUM 3 software package consisting of a CCU
and an iMH software version.
Is indicated by Rel and five digits (X.XX.XX, e.g. 1.01.05) and shows the
level of development of the installed software.
See bobbin
Yarn joint based on the interlacing of the two yarn ends.
Checking of a splice with regard to its mass or diameter increase and
length in the splice channel of the installation.
Fault channel for the detection of thin places.
Classes can be selected by customers.
Faulty yarn mass increase which is at least than 8 cm.
Faulty yarn mass increase which is between 1 and shorter than 8 cm long.
Thick place, very

short
Faulty yarn mass increase (nep) which is shorter than 1 cm.
Thin place, short
Faulty thin yarn section
Upper yarn check
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
Electrical signal, which is continuously determined from the yarn mass or

the yarn diameter in the measuring field.
Joining of two yarn ends by a splice or knot.
USTER QUANTUM 3
Appendix
16.4
16
International Systems of units
16.4.1 International system

During the last decades, most countries have revised the laws referring to measurement determinations. The motivation for this was the introduction of an internationally-recognized system of measuring units which is known under the name of "Systme International d'Units" (abbreviation: SI) or Internationale System of Units. In the European Commuity (EC), the deadline for introducing the SIsystem was already reached at the end of 1977, and in Switzerland, this deadline ran until the end of
1982. Also in the East European countries, a forerunner to this SI-system, the MKSA-system was
legally embodied quite early on, and in Eastern Germany, for instance, even as early as 1958.
16.4.2 'SI' system

Confusion in the system of units during the last decades has often led to quite considerable difficulties
in science and technology, and more particularly in commerce. This resulted, even many years ago,
in various forward-thinking scientists suggesting a reorganization of the system of units. An important
foundation stone, in this respect, was laid by the Italian physicist Giorgi as far back as the year 1901.
His suggestion led, in 1948, to the international recognition of the MKSA-system (meter-kilogramsecond-ampere). All physical units used in science and technology could be related to these four
basic units.
In the year 1960, at a general conference on weights and measures, the SI-system was officially accepted. The SI-system differs from the MKSA-system in that the four referred to fundamental units of
meters, kilograms, seconds and amperes were extended by the Kelvin (temperature), the Mol
(amount of substance) and the Candela (intensity of light) as further basic units.
Although, according to present-day knowledge, every physical size which can be measured can be
related to a combination of these 7 basic units, it is quite frequent to find that certain used combinations have their own name. For instance, in the SI-system, the force unit of kg m/s is allowed to be
referred to as the "Newton" [N]. For work done, which in the SI-system has the unit kg m/s m, the
reference Newton-meter [Nm] or Joule [J] can be used.
As the physical sizes, in some cases, extend over a quite wide range of figures, it is allowed that, for a
decimal multiple or a part of a basic unit, derived units such as milli, deci, kilo, etc., can be applied.
Table 16-1 shows the seven base units of the SI System of Units. All the additional units are derived
from these 7 base units.
Physical parameter
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
SI-units and other legally-allowed units
Conversion
Obsolete units
km, cm, mm
1 m = 1,099 yard
Inch, yard, mile
kg/m
ktex, tex
(1 ktex = 1 g/m)
(1tex = 1 g/km)
1 tex = 1000/Nm
1 tex = 590,5/Nec
Nm, Nec, New,

den, grains/yd,
etc.
kilogram
kg
g, mg, g
1 kg = 2,204624 lbs
Grain (gr), ounce

(oz), pound (lb)
Newton
mN, cN
1N = 0.102 kgf
kg, kg*, kgf, gf,

lb, lbf
Newton/tex
N/tex
cN/tex
1 cN/tex = 0,9807 Rkm
g/tex, Rkm, CSP
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
16.4.3 Conversion table for yarn count systems

In the textile industry, it is often the case that in the same spinning mill both English and metric systems of count determination are used with fiber assemblies. The following table enables the conversion into one or the other of the count systems.
The use of this table is illustrated based on an example:
For a particular yarn the English cotton count Nec = 32 is known. The yarn count in tex is to be determined. One looks fist of all in the column "GIVEN" for the section Nec. In this section one moves
downwards until one reaches tex in the "TO DETERMINE" column. Now one carries out the calculation referred to in this field.
tex =
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
Explanation of the abbreviations

dtex
Decitex
Nec
Cotton hank number
den
Denier
Nel
Linen lea number
g/inch (approx)
Fiber count system (can be determined

with Micronaire type instruments)
New
Worsted hank number
Nm
Metric count
Y.S.W.
Yorkshire skeins woollens
16.4.4 Conversion of English units into metric units

The units referred to in this handbook are primarily metric units In order to be able to convert all the
figures into English units, the more important conversions as used in the textile industry are provided
here.
Name of the unit
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
1 lea (120 yds), cotton
lea
109 m
1 hank (840 yds), cotton
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
1 pound-force (=16 ozf)
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
1 pound-force per square

inch (p.s.i)
lbf/in
1 pound-force per square

foot
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.
Ajgaonkar, D.B.,Principles of Knitting XXXIII, The Indian Textile Journal,163-170, October

1975.
5.
ITMF COTTON CONTAMINATION SURVEY 2009
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.
USTER CLASSIMAT QUANTUM Application Manual, Analysis of yarns by a sophisticated

classifying system, Se 620, May 2008.
14.
USTER ZWEIGLE SPLICE TESTER 4 Application Report: Determination of the strength and
elongation of splices, SE 633, February 2010.
15.
USTER ZWEIGLE SPLICE TESTER 4 Application Handbook, Determination of the strength

and elongation of splices, V1.0, 623 106-04020, October 2009.
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
Uster Technologies AG
Sonnenbergstrasse 10
CH-8610 Uster / Switzerland
Phone +41 43 366 36 36
Fax
+41 43 366 36 37
www.uster.com
Local sales and service organizations under: www.uster.com USTER Support/Tools Customer Support
SW 461 040-10020 Printed in Switzerland Copyright 2011 Uster Technologies AG

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USTER QUANTUM 3

Yarn clearing on winding machines

Textile Technology / V1.0 / April 2011 / 316 050-10020

Basics of yarn measurement and yarn clearing

Disturbing thick- and thin places

Periodic yarn faults

Quality parameters of a yarn

Vegetable Matter Clearing

10 Detection of polypropylene fibers with USTER QUANTUM 3

11 Various settings and applications of USTER QUANTUM 3

12 Clearing of special yarns

13 The first hour at the new clearer system

14 Frequently asked questions

Copyright 2010 by Uster Technologies AG. All rights reserved.

Purpose of the application handbook ....................................................................................... 1.1

Yarn faults and yarn clearer ....................................................................................................... 1.1

Short history of the USTER yarn clearers ............................................................................... 1.3

Origin of seldom-occurring yarn faults ..................................................................................... 1.5

Classification of seldom-occurring thick and thin places ....................................................... 1.7

Allocation of seldom-occurring yarn faults to the Classimat matrix...................................... 1.8

Structure of the USTER QUANTUM 3..................................................................................... 1.11

Features of USTER QUANTUM 3 and options .......................................................................... 1.12

Basics of yarn measurement and yarn clearing .................................................................. 2.1

Purpose of this chapter .............................................................................................................. 2.1

Monitoring of thick places .......................................................................................................... 2.1

Monitoring of foreign fibers in the yarn .................................................................................... 2.7

Disturbing thick and thin places........................................................................................... 3.1

Introduction .................................................................................................................................. 3.1

Definition of the yarn body ......................................................................................................... 3.1

Interpretation of the yarn body .................................................................................................. 3.5

Disturbing thick places ............................................................................................................... 3.5

Clearing limits for thick places .................................................................................................. 3.9

Disturbing thin places ............................................................................................................... 3.14

Clearing limits for thin places .................................................................................................. 3.14

Count variations .................................................................................................................... 4.1

Introduction .................................................................................................................................. 4.1

Count deviations.......................................................................................................................... 4.3

C and CC settings ........................................................................................................................ 4.6

Calculation of yarn count deviations ....................................................................................... 4.12

Example for the setting of the C-channel ................................................................................ 4.18

The effect of count deviations on the fabric appearance ...................................................... 4.19

Splice Clearing ...................................................................................................................... 5.1

Introduction .................................................................................................................................. 5.1

Scatter plot of splices ................................................................................................................. 5.1

Splices .......................................................................................................................................... 5.3

Splice classification of the USTER QUANTUM 3 .................................................................... 5.8

Upper yarn detection (U) ........................................................................................................... 5.13

Minimizing the number of splices ............................................................................................ 5.14

Critical items which affect the number of splices ......................................................................... 5.14

Periodic yarn faults ............................................................................................................... 6.1

Influence of the yarn speed on the winding machine .............................................................. 6.2

Further reasons for periodic defects ......................................................................................... 6.2

Periodic fault registration with the PF ....................................................................................... 6.3

The effect of periodic faults on the fabric appearance ............................................................ 6.6

Quality parameters of a yarn................................................................................................. 7.1

Introduction .................................................................................................................................. 7.1

Yarn evenness ............................................................................................................................. 7.3

Imperfections ............................................................................................................................. 7.10

Class-Alarm ................................................................................................................................ 7.15

Tailored classes (Option Advanced Classes) ......................................................................... 7.19

Adjustment of the individual alarm possibilities .................................................................... 7.22

Indication of ejected bobbins ................................................................................................... 7.33

Criteria to select the limits for quality characteristics ........................................................... 7.33