USTER® QUANTUM 3

The yarn quality assurance system

Application Training

Murali Ganesh, UTIN

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Murali Ganesh, UTIN

How the clearer history began

Mechanical yarn clearer in 1952 by Uster

Technologies

This mechanical element has kept back

disturbing thick places.

Murali Ganesh, UTIN

The birth of the first commercially successful
electronic yarn clearer

In 1960 an electronic yarn clearer by the

name of USTER® SPECTOMATIC was
introduced onto the market and installed
on manual winding machines.

Murali Ganesh, UTIN

USTER® AUTOMATIC yarn clearer
First clearer on automatic winding machines in 1965

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USTER® AUTOMATIC yarn clearer

Murali Ganesh, UTIN

Murali Ganesh, UTIN
New Generation Clearer

Smart Duo
technology

Murali Ganesh, UTIN

 History of Yarn Clearers

• High Resolution

C3/W3 • Self Calibration

Analog Clearers • Signal to Noise ratio
D3
D4 UPM
D5 UPC

Digital Clearers
UQC
UQC2
UQ3
UQ4.0
Murali Ganesh, UTIN
USTER® QUANTUM 3
Intelligent measuring head iMH

Murali Ganesh, UTIN

USTER® QUANTUM 3
Basics of yarn clearing
Claims and their origin

Remaining Contamination,
thicks/thins, 16% 14%

Fabric Barré, 13%

appearance,
15%

Hairiness –
pilling , 12%

Breaks in knitting
/ weaving, 21% White
specs, 9%

Murali Ganesh, UTIN

USTER® QUANTUM 3
Basics of yarn clearing
Definition

Yarn clearing is replacing a disturbing defect

with a less disturbing splice

This means:
– Cut only where it improves quality or performance in downstream
processes
– Make sure that the splice is better than the defect taken out

Murali Ganesh, UTIN

 Origin of defects or “outliers” in spinning mills
Efforts must be made on both fronts – controlling them with yarn clearers
but also preventing them by identifying their sources

Opening Spinning preparation Spinning Winding

Every defect has a cost ! Proactive quality management towards prevention of defects will
help to maintain consistent quality in the final package and keep costs lower.

Murali Ganesh, UTIN

Introduction
Sources of faults

Ambient Raw
Conditions material

Sources of
faults

People / Machines
Practices

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Causes for seldom-occurring yarn faults

A4 B4 D4
C4 by spinning
Caused
preparation and
A3 B3 spinning
C3 D3

A2 Caused by
B2raw C2 D2
material and card
A1 B1 C1 D1

Murali Ganesh, UTIN

Fiber-related faults
Seldom-occurring events/thin places and thick places

S1:
spun-in S3: Long
fly collection
of fly

S2:
loose fly
S5:
Pushed-
together
collections S4: Fish /
of fly corkscrew-
type faults

Murali Ganesh, UTIN

USTER® QUANTUM 3
Basics of yarn clearing
The target of yarn clearing is to eliminate outliers

Fault frequency
Clearing limit, to be defined
by the customer

0%
- 100% Mean value + 100%

Area of the frequent yarn faults Area of seldom-occurring yarn faults

(CV, Imperfections, Hairiness)

Data measured in the Laboratory Monitored by QUANTUM 3

Defective bobbins are eliminated Replaced by a splice

Murali Ganesh, UTIN

 1

Murali Ganesh, UTIN

Defining clearing limits – Basic approach
The approach here is valid for limits for all defect types  understand the
normal yarn variations and define limits sufficient to eliminate exceptions

Too open
Mass or diameter variation

Optimized

Too close

Optimized
Too open

Length
Note: Diagram for illustration purposes only

Murali Ganesh, UTIN

USTER® QUANTUM 3
YARN BODYTM
Definition

The YARN BODYTM is composed of two parts:

• Dark green area representing the real YARN BODYTM
• Light green area representing YARN BODYTM variations

Murali Ganesh, UTIN

Murali Ganesh, UTIN
USTER® QUANTUM 3
Smart Clearing TechnologyTM
Smart Limits based on YARN BODYTM

• The Smart Limit function proposes a starting point for the clearing limits based
on the YARN BODYTM , Uster knowhow and CLASSIMAT® classes
• The system also provides a cut forecast to facilitate faster setup of clearing
limits.

Open setting Close setting

Murali Ganesh, UTIN

USTER® QUANTUM 3
Optimized settings with Smart Clearing TechnologyTM
Practical examples for optimizing NSLT setting

China, 90% cotton/10% PES, Ne 40/1, carded, knitting, 1500 m/min

Small adaptations will help to reduce the cuts using the Smart limit function

Before optimisation After optimisation

Murali Ganesh, UTIN

USTER® QUANTUM 3
Practical examples for NSLT setting
Origin of the defects

Defetcs resulting from drafting problems and dirt fluff accumulations

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USTER® QUANTUM 3
Origin of Exceptions

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USTER® QUANTUM 3
Origin of Exceptions

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USTER® QUANTUM 3
Origin of Exceptions

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USTER® QUANTUM 3
Origin of Exceptions

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USTER® QUANTUM 3
Origin of Exceptions

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USTER® QUANTUM 3
Origin of Exceptions

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Cause of quality defects (Examples)

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Cause of quality defects (Examples)

Second top roller incorrect position

Top arm pin not in correct position

Bottom apron tension liver waste

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Murali Ganesh, UTIN
Murali Ganesh, UTIN
Murali Ganesh, UTIN
Murali Ganesh, UTIN
Murali Ganesh, UTIN
Murali Ganesh, UTIN
Murali Ganesh, UTIN
Optimum Clearing curve

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Practical examples for NSLT setting
Too many cuts as a result from ring spinning
might lead to settings being too open

Old
setting

New
setting

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Is it Optimized

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Is it an Optimum Setting

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Back process identification

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Back process identification

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Back process identification

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30 combed hosiery

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USTER® QUANTUM 4.0
Cross Clearing
Assistance between two measurement principles
Security Prevention

Uster Quantum 4.0 can analyze and compare both the capacitive and optical signal at the same time.

• For the cross clearing function,

the capacitive sensor is in the
lead.
• After evaluating the yarn based
on the mass signal, a second
evaluation takes place utilizing
the optical signal

• There is no need to define a second clearing limit, it simply needs to be selected a sensitivity level like
open – medium – close
• Cross clearing cuts will mainly happen under bad ring-spinning conditions.
• For instance, cross clearing cuts X can indicate that the cleaning on the rings spinning machine is overdue

Murali Ganesh, UTIN

USTER® QUANTUM 4.0
Cross clearing
Event report for cross clearing cuts X

Function
• Cross clearing is utilizing
the capacitive and the
optical signal one after the
other
Impact
• The X cuts are detecting
events passing below the
capacitive limits but having
a significant diameter
increase.
• The display of the X cuts is
showing the diameter
increase [%] and the length
in [mm]

Murali Ganesh, UTIN

USTER® QUANTUM 3
Fabric defect created by count mix up

Reference fabric Defective fabric

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USTER® QUANTUM 3
Barée effect due to count deviations

• Long thick/thin places, which are mainly disturbing due to their length, not so
much due to their increase/decrease of mass/diameter
• Real deviations from the yarn count (several reasons)
• Several short, successive events, which are disturbing as a whole in the end
product

Reference fabric Defective fabric

Murali Ganesh, UTIN
USTER® QUANTUM 3
Settings of C channel
The system shows the boundary for each cut length

Murali Ganesh, UTIN

USTER® QUANTUM 3
Practical example for setting of C
C reference length recommended to be 8 to 10 meters

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Back Process identification

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USTER® QUANTUM 3
Smart limits for CC channel

Even as the channel has been extended for multiple lengths,

the settings process is made easier

Murali Ganesh, UTIN

USTER® QUANTUM 3
Practical example for setting of CC
CC setting is too close resulting in many cuts

This setting is very close to the YARN BODYTM, analyzing these bobbins giving
CC alarm will not show a high number of outliers.

Murali Ganesh, UTIN

USTER® QUANTUM 3
Practical example for setting of CC
CC setting should be balanced between 2 and 12 meters

This setting is very close to the YARN BODYTM at 2,0 meter reference length,
but for 12,0 meter the setting is too open.

Murali Ganesh, UTIN

USTER® QUANTUM 4.0 Security Prevention
Density: Feature overview

Combining the optical and capacitive signal, USTER® QUANTUM 4.0 is able to monitor the yarn density, both
continuously and after every splice

Low twist, slipping spindles

Blocked compact device
Carded roving instead combed
Mix up of yarn qualities of same or different
count

High twisted yarn

Off-center core
Combed roving instead carded
Mix up of yarn qualities of same or different count

• Protects from mix-up of yarns with different twist levels

• Prevents issues deriving by malfunctioning of the compacting device
• Prevents mix ups of different materials or blends of same or different count in the winder

Murali Ganesh, UTIN

USTER® QUANTUM 4.0 Security Prevention
Density: Feature overview
setting hints

Density D after every splice Continuous density CD during the

whole winding process
• For Density D the reference length
should be set at minimum 12 meters • For CD the reference length is fixed at 2
and about +/- 15% to start with meter up to 12 meter
• The setting at 2 meter should be open
like 20 – 30%, but at 12 meter it can be
as close as needed.

Murali Ganesh, UTIN

USTER® QUANTUM 3
Periodic fault in yarn on a taper board

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USTER® QUANTUM 3
Periodic fault setting

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 USTER® QUANTUM 4.0 Security Prevention
Swarm clearing: Feature overview

Swarm clearing detects faults that are concentrated in a certain area of the yarn, below the clearing limits.
Those faults are not disturbing as individuals, but due to their concentration on a short length, they will result
in fabric appearance issues.
• Swarm clearing is the solution
for non periodical defects
• Detected faults can be thick /
thin places or Foreign Fibers
• Multiple defects can be
eliminated with a single cut,
resulting in less overall cuts (and
splices)
• Faults concentration is avoided,
protecting the fabric appearance

• Protects the final yarn quality, reducing cuts and splices

• Prevents issues in fabric appearance, related to Swarm events

Murali Ganesh, UTIN

 USTER® QUANTUM 4.0 Security Prevention
Swarm clearing: Feature overview
setting overview

The swarm clearing is a perfect addition to the PF channel for periodical defects. For thick places, but it is
also available for thin places and foreign fibers.

Max. events:
How many events need to be within
this region to initiate a cut

Reference length:
Evaluation length for the number of
events

Swarm sensitivity:
Percentage below the clearing limit

Min fault length:

Defects starting from cm length

Max fault length:

Defects up to cm length

Murali Ganesh, UTIN

USTER® QUANTUM 3
Splice clearing
Easy adjustment to NSLT

Murali Ganesh, UTIN

USTER® QUANTUM 4.0
Security Prevention
Group settings
JA Splice alarm

Function
To have a fast and reliable indication
about the splice performance a JA
splice alarm can be set.

Impact
Every splice cut will increase the
counter by one, every splice done will
reduce this counter, but not below zero.
If the limit is overstepped an alarm will
be initiated.

By this positions can be alarmed in a

reliable way if there are multiple splice
defects in a row.

Murali Ganesh, UTIN

USTER® QUANTUM 3
Core yarn production
Typical problems from the mill

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USTER® QUANTUM 3
Core Yarn Clearing

Core Yarn Clearing Option – The Solution

• USTER® QUANTUM 3 tackles Core Yarn issues

with new Yarn Clearing options.

• Unique USTER® Sensor combinations detect

-Missing Core (MC) and
-Off-center Core (OC)
-when yarn fault appears at a significant level
over long lengths.
Please keep in mind:
• The Missing Core feature is available for the
capacitive clearer only
• Both Core Yarn features are available with the
Foreign Matter option only.

Murali Ganesh, UTIN

USTER® QUANTUM 3
Core Yarn Clearing
Display of actual variation and Smart Limit proposal

Special yarn type:

Core Yarn

Display of actual values

Smart Limit proposal

Murali Ganesh, UTIN

 USTER® QUANTUM 4.0 Security Prevention
Continuous core detection: Feature overview

The Core yarn option can detect missing core and off-center core, thanks to the combination of optical and
capacitive sensors.

• Second iteration of the Core Yarn

option, that had a great success in
the market
• Now also able to detect missing core
and off-center core continuously
• This is possible thanks to the new
electronics, and higher processing
power

• Protects yarn quality from missing and off-center core issues, now also continuously
• Prevents all the related issues in fabric appearance, related to missing and off-center core

Murali Ganesh, UTIN

USTER® QUANTUM 3
The most advanced foreign matter sensor
2 different light sources in parallel

New foreign matter sensor

• Multicolored light sources

• Detection of all colors

• Detection of fine and short

foreign fibers

Murali Ganesh, UTIN

USTER® QUANTUM 3
FD detection with multi colored LED

Screen Comment

Function
Detection of foreign fibers by
analyzing the reflection of the
yarn using 2 different LED-
colors

Impact
All events starting from 2mm
length and 3% reflection on
can be classified, counted and
compared to the clearing limits

Murali Ganesh, UTIN

USTER® QUANTUM 3
FD detection with multi colored LED
Example of clearing limits

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USTER® QUANTUM 3
Vegetable Matter Clearing

Three different settings possibilities

(Extra Close, close, medium, open, Extra close)

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 USTER® QUANTUM 4.0 Security Prevention
Advanced FD classification: Feature overview

USTER® QUANTUM 4.0 now offers the possibility to view an advanced FD

classification
• For FD additional
classes below the 5%
line are now available
FD advanced
classification • Especially for bleached
white applications in the
high-quality sector, the
foreign fiber clearing
needs to be more
sensitive than only 5%
deviation.
• This region was not
expressed by
classification values like
on UQ 3 so far.
• The advanced classification adds now even more details to the contamination content of the yarn

Murali Ganesh, UTIN

USTER® QUANTUM 3
Mélange and colored yarn clearing
FL + FD working in parallel for colored yarn

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USTER® QUANTUM 3
Shade Variation

“Mixed-up Colors and Shade Variation” – The Solution

• Mixed-up colors and shade variations are

detected now in colored and mélange yarns with
USTER® QUANTUM 3.

• Unique USTER® Sensor combinations detect

- Shade Variations (SV, CSV) automatically from
the base yarn

Please keep in mind:

• Detection of shade variation with USTER’s
advanced Foreign Matter Sensor only.

Murali Ganesh, UTIN

USTER® QUANTUM 3
Shade Variation

Potential Quality Issues – “Mixed-up Colors and Shade Variation” Impacts

• Yarn colors or shades mixed-up during

production process

• Mistakes often detected only on yarn package

or in final fabric
• Valuable resources are wasted and the risk to
run into a major claim is high.

Murali Ganesh, UTIN

USTER® QUANTUM 3
Shade Variation
Setting page for SV

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USTER® QUANTUM 3
Shade Variation
Setting page for CSV with Smart Limit proposal

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USTER® QUANTUM 3
Shade variation
differences nearly invisible for the human eye can be detected

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 USTER® QUANTUM 4.0 Security Prevention
Blend mix-up: Feature overview

The Blend mix-up can detect cops with a different material composition being mixed up in greige yarns.

• Blend mix-up is answering a long

pending need of the market in raw
white blend production
• This measurement is continuously
checking the yarn for a mix-up of
different material blend.
• This function is not designed for
controlling the blend variation within
a defined blend ratio.

• Protects yarn quality from mixing up cops with different material blends
• Prevents all the related issues in fabric appearance, related to missing and off-center core

Murali Ganesh, UTIN

USTER® QUANTUM 3
PP defects

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USTER® QUANTUM 3
PP Clearing

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 USTER® QUANTUM 4.0 Security Prevention
PP classification: Feature overview

Uster Quantum 4.0 now offers the possibility to view PP classification

• Is now possible to obtain a full

PP classification of the PP content of the
classification yarn
• This assists the setting of a PP
clearing limit

• The new PP classes offers a specific overview of the content of Polypropylene in the yarn

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USTER® QUANTUM 3
Difference between IP values and exceptions

Neps Thicks Thins

(+200%) (+50%) (-50%)

Imperfections Seldom-occurring
Faults

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USTER® QUANTUM 3
Special Functions
Textile alarm

Textile Alarm Comment

Function
The textile alarm will identify
bobbins initiating too many cuts
of a certain type within a given
length

Impact
By setting textile alarm, e.g. 10
per 1km the bobbin will be
stopped if the se limits are
violated. The defective bobbin
can be taken out of the
production process.

Murali Ganesh, UTIN

 USTER® QUANTUM 4.0 Security Prevention
Special functions

YA1: Feature overview

Uster Quantum 4.0 now offers a combined yarn alarm YA1.

• The YA1 is combining different cut

types to generate an alarm for a faster
detection of outlier cops.
• It is combining N, S, L, T, C, CC and
MC cuts to one individual alarm limit.
• The YA1 can be adjusted alone or
combined with the individual alarm
features
• The individual alarms can still be added
as needed.

• Some issues from spinning are not only generating one type of defects. Therefore, a combined yarn alarm
helps to detect outlier cops much faster and reliable.

Murali Ganesh, UTIN

USTER® QUANTUM 3
Q-Data Function
CVm%

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USTER® QUANTUM 3
Q-Data Function
Hairiness (H)

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USTER® QUANTUM 3
Q-Data Function
Imperfection (IPI)

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USTER® QUANTUM 3
Q-Data function
Class Alarm

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Used case of Class Alarm

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 USTER® QUANTUM 4.0 Flexibility
Central Smart Limit button: Feature overview

USTER® QUANTUM 4.0 offers a central Smart Limit button, located on the overview screen

• After the reference length for

the individual channels are
reached, all available smart
limits can be adjusted with
just one single tap
• The changed parameters will
be highlighted in blue color
• All changes can be accepted
together, or the individual
limits can be fine tuned
separately, according to the
user preferences

• User friendly and easy to set up

• Changing articles and applying new limits for new products has never been easier

Murali Ganesh, UTIN

USTER® QUANTUM 3
Data Display
Display of Textile alarms

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USTER® QUANTUM 3
Special Functions
Additional classes

Additional classes Comment

Function
Additional classes are used
mainly for even yarn types like
compacted yarn, Sirospun yarn
or folded yarn

Impact
Beside the standard classes
another 18 classes become
available

Murali Ganesh, UTIN

USTER® QUANTUM 3
Unique package for total quality – Tailored classes

Tailored Classes Settings – Users can

easily define their own fault classes!

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Data Display

Murali Ganesh, UTIN

Murali Ganesh, UTIN