UT4_Application Report - Uster Technologies

THE YARN QUALITY ASSURANCE SYSTEM3.7 What is the USTER ® QUANTUM 3 advantage withrespect to compact yarns? ........................................................ 133.8 When should I use the vegetable clearing? ............................... 143.9 Why can not all vegetables pass using Vegetable MatterClearing when they are not disturbing? ..................................... 143.10 We have an USTER ® QUANTUM clearer or other clearergenerations - can we copy the setting because it wasacceptable until now?............................................................... 153.11 What is different with the short count channel? Is the settingsprocess easier?......................................................................... 153.12 How can one set up the splice clearing curve? ......................... 153.13 What FD setting should I keep for a cotton yarn?(In case of no specific requirement from the buyer) ................... 163.14 USTER ® QUANTUM 3 has more than 40 classes, but inUSTER ® QUANTUM2, we only have 23 classes-What is the purpose of these additional classifications inUSTER ® QUANTUM 3? ............................................................ 163.15 USTER ® QUANTUM 3 has new sensor technology in basicand FM clearing – are the results comparable to the oldclassification? ........................................................................... 173.16 Is the USTER ® QUANTUM 3 classification comparable to theUSTER ® STATISTICS? ............................................................ 183.17 Can I use the QUANTUM 3 for wet splicer applications? .......... 183.18 Is it possible to classify foreign fibers? ...................................... 193.19 What are the experience values for cuts in ring spinningmills with foreign fiber clearers? ................................................ 193.20 With the UQC2 one could not compare the classificationof C15 and C20 – how is it now? ............................................... 194 (21) USTER ® QUANTUM 3

THE YARN QUALITY ASSURANCE SYSTEM1 IntroductionThis paper was written to answer the questions which are asked frequentlyby our customers.2 Product related questions2.1 What type of sensing principles does USTER ®QUANTUM 3 offer?USTER ® QUANTUM 3 offers the choice of optical and capacitive sensingtechnologies for basic clearing. The foreign matter option can be added ontop 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• Polypropylene clearing – C15 F30 PP and C20 F30 PP2.2 How does the USTER ® QUANTUM 3 differ from competingproducts?The USTER ® QUANTUM 2 was until now the market leader and thebenchmark for high performance yarn clearing. The USTER ® QUANTUM 33, the successor, takes yarn clearing to a next level. The system was designedbearing the needs of a range of requirements starting from basicusers to the most sophisticated demands. It incorporates futuristic technologywhile at the same time being robust to withstand the challenging millenvironment.The core of the USTER ® QUANTUM is its smart clearing technology. Ithelps to eliminate the basic and most important challenge for spinnerswhich is the definition of the optimum clearing limit for a variety of yarnswith differing quality needs. USTER ® QUANTUM 3 has simplified the complexitiesof yarn clearing and enables valued users to easily and fully exploitall clearer capabilities, every day. The system learns and displays theyarn body (nominal yarn with its set of tolerable frequently occurring yarnfaults) in minutes and at the press of a button proposes a starting point forclearing limits with a cut forecast. Practically this is equivalent to having anUSTER ® specialist always beside to achieve the optimum results out of anyyarn application.USTER ® QUANTUM 3 5 (21)

THE YARN QUALITY ASSURANCE SYSTEMThe new USTER ® QUANTUM 3 will also amaze you with its speed andease of use. In just two minutes, it will learn everything it needs to knowabout your yarn.Then, applying USTER ® knowhow it will suggest the best way to achievethe quality requirements you specify, by proposing suitable clearing limits.You now only need to approve and hit the START buttonThe USTER ® QUANTUM 3 with its new foreign matter clearing conceptalso sets a new benchmark for contamination control.• The new sensor technology is able to see all colors of foreign fibers andseparates them into disturbing foreign fibers and mostly non disturbingvegetables to enable maximum removal of foreign fibers with minimalcuts.Polypropylene detection is another key highlight. Founded on the new capacitivesensor technology, USTER ® QUANTUM 3 sets a new benchmarkfor PP removal.In summary the USTER ® QUANTUM 3 is the most robust and technologicallyadvanced knowledge integrated clearer ideally suited to today’s marketneeds, far ahead of any competing products.2.3 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 thelowest possible cuts• Fast and easy setup of appropriate clearing limits - One button proposalfor clearing limits considering the yarn body and requirements as astarting point for optimization• Easy selection of the appropriate clearing limit with up and down buttons• Cut forecast for the selected clearing limitSmart count clearing• Detection and elimination of bobbins with wrong counts• Detection and elimination of short term mass/diameter variations oflength ranging from 2 m to 12 m having a major negative impact on fabricappearanceDetection of periodic defects (spectrogram peaks) of multiple wavelengths6 (21) USTER ® QUANTUM 3

THE YARN QUALITY ASSURANCE SYSTEMAdvanced splice clearing• Synchronized to clearing limits to ensure safe quality• Scatter plot and numeric classification of splices to identify and eliminaterogue splicersForeign Matter clearing• Detection of all colors of foreign fibers using multiple light sources• New foreign fibre clearing concept separating foreign matter into foreignfibers and vegetable matter. This allows the most effective and economicremoval of disturbing foreign fibers ever.Next generation of Polypropylene detection with a higher removal efficiencyof PP including small PP at high cut efficiency.A new faster control unit with the latest generation touch screen and anergonomic interfaceThe next generation Expert system with a host of smart features – TheUSTER ® QUANTUM EXPERT 3.2.4 What are the new quality parameters measured by theUSTER ® QUANTUM 3?The USTER ® QUANTUM 3 detects short, fine thick and thin places in newclasses – see picture belowFault size (%)+400+250+150+100+75+45+350A4A3A2A1A0B4B3B2B1B0C4C3C2C1C0CP1D4D3D2D1D0DP1DP0EF GF01 F02 G01 G02Existing classesNew classes-25-30-45-75TB1TB2TC1TC2TD0TD1TD2H01 H02 I01 I02H1 I1H2 I20.1 1 2 4 8 32Fault length (cm)Fig. 1Designation of the thick andthin places classesUSTER ® QUANTUM 3 7 (21)

THE YARN QUALITY ASSURANCE SYSTEMFig. 2Designation of the foreignfiber and vegetable classesShort count variations (CC) of multiple cut lengths i.e. 2 m to 12 m (Forcomparison: USTER ® QUANTUM 2 – only one cut length)Periodic faults of multiple wavelengthsAll colors of foreign fibers including those with very low contrast or reflectanceEven small Polypropylene defectsAs always the quality data is on the same basis as the established Usterlaboratory instruments2.5 What is the yarn count range of USTER ® QUANTUM 3and which sensing method will fulfill the quality requirement?The USTER ® QUANTUM 3 yarn count range is extended compared to theUSTER ® QUANTUM 2 and can be used for all staple fiber yarns from Nec 3– Nec 200 / Tex 100 – Tex 2.9. The choice of either an optical or a capacitivesensor gives the widest application range. USTER ® will assist you inthe choice of sensing method best for your quality requirements.2.6 What is new with the USTER ® QUANTUM 3 optical basicclearer?USTER ® QUANTUM 3 comes with complete new sensor technology for allsensors including the optical basic clearing. The new optical sensor is ableto see the complete yarn body and suggest clearing limits for all applications.8 (21) USTER ® QUANTUM 3

THE YARN QUALITY ASSURANCE SYSTEMIn addition to the advanced short thick place detection, the system has newalgorithms for detection of long thick and thin places and also offers thenew advanced count and CC channel to detect short term diameter variationsfrom 2 m to 12 m.Splice clearing is taken to the next level with USTER ® QUANTUM 3 and theclassification (numeric and graphic) is offered with the new optical clearer.As with USTER ® QUANTUM 2, Q Data monitors all quality parameterssuch as CV, Imperfections and classification on the same basis as a thelaboratory.2.7 What is the difference to UQC2 Vegetable Filter?The USTER ® QUANTUM 3 separates foreign matter into three pools. Itprovides online classification of foreign fibers (FD and FL) as before and forthe first time Vegetable Matter Classification. Users can see the amount ofvegetables illustrated as dense areas or from the numeric vegetable classificationmatrix for different cotton varieties.Another innovation is that the system provides a choice of four differentclearing limit possibilities for vegetables. With this the users can choose thelevel of vegetable clearing needed depending on the end use.2.8 What is the advantage of the USTER ® QUANTUM 3 forcore yarns?The main problem with core yarns (with respect to yarn clearing) is the detectionof the missing core. When a core is missing, it causes a marginalchange in diameter however it causes a higher change in mass. The capacitiveclearer has therefore an advantage for this application. The changein mass is proportional to the fineness of the core.The USTER ® QUANTUM 3 has a new capacitive sensor technology whichhas an even better signal ratio and therefore a higher possibility to detectthe missing core. The detection is mainly possible when the change inmass due to the missing core is greater than 5-6%.2.9 What is the benefit of Slub yarn setting in USTER ®QUANTUM 3?The USTER ® QUANTUM 3 clearing concept based on yarn body helps toeasily define the boundaries for clearing disturbing defects in such yarnswhile retaining the slubs produced on purpose.USTER ® QUANTUM 3 9 (21)

THE YARN QUALITY ASSURANCE SYSTEMThe K-point setting will easily help to keep these purposely produced slubsaway from clearing. All other defects, which might disturb the fabric appearance,can be taken out.2.10 How is the PP performance of the new clearer?The USTER ®technology.QUANTUM 3 PP clearing is based on the newest sensorThe new PP sensor has high detection efficiency with a high cut accuracyresulting in reduction of disturbing PP in the fabric like never before.The illustration by means of the scatter plot enables to choose or fine tunethe clearing limits in an easy and reliable way.2.11 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 3is a tough, robust clearer which will need less maintenance and repairs andtherefore lower running costs.2.12 What are the advantages from a maintenance point ofview?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 thanconventional clearers. This has been proven in extensive tests in challengingenvironments.The electronic assembly is better shielded to prevent dust and dirt and isalso better isolated from the vibrations of the cutter. This ensures higherperformance stability and the enhanced lifecycle.As a result of the above, users can expect a long lasting, less maintenancedemanding clearer with solid performance.10 (21) USTER ® QUANTUM 3

THE YARN QUALITY ASSURANCE SYSTEM2.13 Can the USTER ® QUANTUM 3 is installed on winders ofprevious generations?USTER ® QUANTUM 3 with its versatile design can also be used for retrofitson older automatic winders. Please refer to the Technical Data Sheet onwww.uster.com to see the list of winder models. Our sales organization willbe glad to assist you in all respects.2.14 Why does the USTER ® QUANTUM 3 has a bigger housing?USTER ® QUANTUM 3 is USTER’s biggest clearer to date - quite simply tofit all new robust technology. Tough on the outside, it’s completely newlydesigned to stand up to the most demanding mill environments and providea 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 fromboth the yarn and the air supply. These QUANTUM 3’s innovations will helpthe 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 betterperformance. The foreign matter sensor for example is higher and widerthan before, which reduces dirt deposits and therefore needs less cleaningand maintenance.2.15 What is the purpose of the arrow LEDs on the measuringhead?The LEDs as in the case of USTER ® QUANTUM 2 are used to display textileor technical alarms. In case of a textile alarm – both arrows light up andin the case of a technical alarm both LEDs blink continuouslyThe arrow LEDs is also used in the test mode to collect defects. Each arrowLED can be programmed for a specific fault type. Please refer to theoperating instructions for more de-tails about the several possibilities withthe test mode – called the iMH LED function.USTER ® QUANTUM 3 11 (21)

THE YARN QUALITY ASSURANCE SYSTEM3 Application related questions3.1 What kind of yarn clearer do I need for my application?It depends on the type of application. Only Uster Technologies offers theknowledge and possibility of the best capacitive and optical clearer for themonitoring and elimination of seldom-occurring thick and thin places. Bothtypes are available with the possibility of optical clearing for foreign fiberelimination. The sales staff and specialists of Uster Technologies can helpyou to select the best option for your application.3.2 How is it possible to simplify the definition of clearinglimits?With the USTER ® QUANTUM 3 Uster Technologies has developed a completelynew, easy and customer oriented way of setting the clearing limits.At first the system can be started up with existing clearing limits. After acouple of minutes of production, the USTER ® QUANTUM 3 analyzes theyarn 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 tobe expected.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 theup/down buttons or of course manually enter the settings.3.3 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 andfaster like never before. After evaluating the yarn over a few kilometers, thesystem proposes an optimum starting point for the clearing limits consideringthe yarn body, experience and requirements. At the same time the systempredicts the number of cuts per 100 km to be expected for the definedlimit. This is available at the touch of a button.In case the default starting point has to be changed for some reasons, userscan simply choose from a range of closer or more open limits each timelooking at the cuts that should be expected for the setting.Thus the optimum setting is based on the smart limits within a short timeAccording to the quality level of the end user required, the settings can beselected more open or close.12 (21) USTER ® QUANTUM 3

THE YARN QUALITY ASSURANCE SYSTEM3.4 What is the best basic setting for my yarn?The best setting is a compromise between quality and productivity. TheUSTER ® QUANTUM 3 proposes an optimal starting point after a couple ofminutes of production. This setting fulfils most end user needs.3.5 How can one find the optimum setting for good fabricappearance and for optimum productivity?The new unique feature of the yarn body display is showing the real characteristicof the yarn for the first time.After just 30 km of yarn running, the yarn body is illustrated and optimizationcan already be started. If higher accuracy of cut prediction is soughtone 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 leftand good fabric appearance.3.6 Which setting shall I use to make sure that no Classimatobjectionable faults will remain?The scatter plot and the yarn body are displayed according to the classes.The USTER ® QUANTUM 3 considers objectionable faults according toClassimat as a criterion when proposing clearing limits.Where needed, the clearing limits can be easily adopted manually to ensurethat no major defects will remain in the yarn (to date).3.7 What is the USTER ® QUANTUM 3 advantage with respectto compact yarns?The USTER ® QUANTUM 3 offers major advantages for compact spinners.Compact yarns are very even, and small defects can be disturbing in thefabric. USTER ® QUANTUM 3 shows the complete yarn body and hence itis possible to clearly identify and remove the outliers even if they are smalland fine. At the same time the unjustified cuts are minimized. Since yarnfaults can easily be recognized by the human eye due to missing hairiness,the USTER ® QUANTUM 3 is particularly suitable to detect smallfaults. Therefore the USTER ® QUANTUM 3 is the most powerful clearer forcompact yarns.Trials with different compact yarn producers have shown that the fabricproduced out of USTER ® QUANTUM 3 cleared yarn is the best.USTER ® QUANTUM 3 13 (21)

THE YARN QUALITY ASSURANCE SYSTEMcmFig. 4Designation of the foreignfiber and vegetable classesThe USTER ® QUANTUM 2 already offers extended classes in thick andthin places and extended classification in Foreign Fiber classification.USTER ® QUANTUM 3 offers these classes and further newer classes inthick and thin places with the option Advanced Classification.The new classes were defined due to the reason that yarns have becomemore even and defects in these newly defined area have been seen to becausing quality claims. For the first time spinners can measure and thereforecontrol these defects.3.15 USTER ® QUANTUM 3 has new sensor technology inbasic and FM clearing – are the results comparable tothe old classification?The new sensor for the detection of thick places and thin places is able tobetter determine the length and size of short thick places and the small thinplaces than the previous sensor. This more accurate determination forshort thick places does not affect the fault categories which have to beeliminated.Foreign matter is detected by a sensor with multiple light sources which isable to deter-mine all colors with the same sensitivity because of improvementsof the optical measuring system. However, the counts per categoryremain within the statistical variations which have to be expected for seldomoccurring events when comparing with the previous measuring systems.USTER ® QUANTUM 3 17 (21)

THE YARN QUALITY ASSURANCE SYSTEM3.16 Is the USTER ® QUANTUM 3 classification comparableto 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 becompared with the USTER ® STATISTICS. It has to be taken into consideration,however, that the environmental conditions are not the same on themachine and in the laboratory, and, therefore, we have to compare the figureswith more tolerance than between two laboratory systems.Fault size (%)+400+250+150+100+75+45+350A4A3A2A1A0B4B3B2B1B0C4C3C2C1C0CP1D4D3D2D1D0DP1DP0EF GF01 F02 G01 G02Existing classesNew classes-25-30-45-75TB1TB2TC1TC2TD0TD1TD2H01 H02 I01 I02H1 I1H2 I20.1 1 2 4 8 32Fault length (cm)Fig. 5Designation of the thick andthin places classescmFig. 6Designation of the foreignfiber and vegetable classes3.17 Can I use the QUANTUM 3 for wet splicer applications?The USTER ® QUANTUM 3 optical clearer can be used with wet splicerwithout any restrictions.The capacitive clearer can be used with restrictions on the amount of watersprayed. Please contact USTER ® for support.18 (21) USTER ® QUANTUM 3

THE YARN QUALITY ASSURANCE SYSTEMFor 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 theseclearers particularly assigned for the wet spliced applications.3.18 Is it possible to classify foreign fibers?The USTER ® QUANTUM 3 classifies foreign fibers and vegetables in theUSTER ® FOREIGN CLASS matrix. The faults are classified according tothe reflection (%) and length (mm). The system also illustrates the frequencyof foreign fibers and vegetables as dense areas to facilitate easy settings.The system provides numeric classification and the scatter plot of foreignfibers and vegetables including the dense area display.3.19 What are the experience values for cuts in ring spinningmills with foreign fiber clearers?Cuts will depend on the degree of contamination of the raw material andthe quality requirements.With medium degree of contamination of the raw material and nonbleached fabrics end use it could be expected that the foreign fiber cutsrange between 10 to 40 cuts per 100 km. In case of bleached knitted orwoven fabrics FF clearing is more critical and even higher cuts should beexpected.With the new FF clearing concept, The USTER ® QUANTUM 3 ensures thehighest possible quality with the lowest possible cuts. The smart way ofsetting the clearing limits of the yarn clearer will ensure that the most disturbingfibers will always be eliminated first. Closer settings will eliminatefiner and shorter faults.3.20 With the UQC2 one could not compare the classificationof C15 and C20 – how is it now?The USTER ® QUANTUM 3 new capacitive sensor has shorter guardedmeasuring fields (4mm). As a result of the new technology, the classificationof C15 and C20 is comparable.This means the clearing limits can be similar between these clearer typesand the cuts, clearing performance for C15 or C20 is comparable. Userscan now choose the most appropriate iMH type for their application.USTER ® QUANTUM 3 19 (21)

THE YARN QUALITY ASSURANCE SYSTEMUster Technologies AGSonnenbergstrasse 10CH-8610 Uster / SwitzerlandPhone +41 43 366 36 3620 (21) USTER ® QUANTUM 3

THE YARN QUALITY ASSURANCE SYSTEMFax +41 43 366 36 37www.uster.comsales@uster.comUSTER ® QUANTUM 3 21 (21)