Various settings and applications of USTER QUANTUM 3

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Main Contents

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

11.2 Display of Data and Alarms ...................................................................................................... 11.3

11.2.1 Display of Data and Alarms with the help of bar graphs ............................................................. 11.3
11.2.2 Display of Data and Alarms with the help of exception reports ................................................... 11.6
11.2.3 Display of yarn faults with the help of textile alarms.................................................................... 11.7
11.3 Collecting defects ...................................................................................................................... 11.9
11.3.1 Introduction .................................................................................................................................. 11.9
11.3.2 Event display by the red light at the sensor (iMH-LED) .............................................................. 11.9
11.3.3 Yarn fault cards ......................................................................................................................... 11.10

11.4 Monitoring of winding functions ............................................................................................ 11.12

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11.4.1 Monitoring of the yarn joint process with the USTER QUANTUM 3 ........................................ 11.15
11.4.2 Monitoring of the settings .......................................................................................................... 11.15
11.4.3 Splice classification ................................................................................................................... 11.15
11.4.4 Yarn jump monitoring (JPM, JPA) ............................................................................................. 11.16
11.4.5 Drum signal monitoring (DSM) .................................................................................................. 11.17
11.4.6 Drum wrap monitoring (DWM, DWA) ........................................................................................ 11.17
11.4.7 Cut monitoring CTM .................................................................................................................. 11.18
11.4.8 Zero point monitoring ZPM ........................................................................................................ 11.18

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Various settings and applications of USTER QUANTUM 3

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11 Various settings and applications of USTER® QUANTUM 3

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 differ-
ent 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.

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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 Comparison of the chosen smart limit to original article clearing limit

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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 (ca-
pacitive 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 Recalling the factory settings of the default articles (capacitive (left) and optical (right))

11.2 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.

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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

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Fig. 11-7 Machine summary submenu in the “Display” main menu

Another new function is given with the easy screen buttons starting from SW 1.10.12 and above. With
the button up to 8 display screens can be added on the easy button bar. The same button can
be used to dismiss these buttons if not of interest any more. This will help the quality manager as well
as the maintenance staff to have easy access to the data needed most.

In Fig. 11-8, an example of these bar graphs is given. Here the category is “Yarn Faults YF” and fea-
ture is YF (see Fig. 11-5). As it can be seen on Fig. 11-8, 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.

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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. 11-8 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 thresh-
olds 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.

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Fig. 11-9 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. 11-10 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

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Fig. 11-11 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. 11-12, 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. 11-12, 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. 11-12 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 Technical Alarm

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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 dis-
plays 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
• Murata QPro
• Savio Espero
• Savio Orion
• Savio Polar
• Qingdao Smaro
• Qingdao Spero

The iMH LED display function can be assigned to the whole machine, one group or a range of wind-
ing positions.

When the programmed cut occurs:

• the iMH cuts
• iMH LED flashes according to the selection
• red winding position lamp lights up continuously.

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The user should enter the range and cut type for the 3 display variants. These are:

Fig. 11-13 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. 11-13, right), the yarn faults / cuts are also displayed showing the size / inten-
sity 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. 11-14, left). The selected events are displayed with date, time
and winding position information (Fig. 11-14, right).

Fig. 11-14 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.

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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 polypro-
pylene 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 Yarn: Ne 30, 100% cotton, combed, bobbins
Sensor: iMH C15F30 Sensor: iMH C15F30
S-faults FD-faults

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Fig. 11-15 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 sup-
port 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.

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11.4 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 signal sensor (DSM)
• Splice Alarm (Joint, JRA) • 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
• Don’t cut drum wrap (Orion (Polar only),
Espero, Smaro, Spero
• DSM Drum Signal monitoring (most ma-
chines)
• Don’t cut drum wrap (Orion (Polar only),
Espero, Smaro, Spero

Fig. 11-16 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

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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 measur-
ing 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 mo-
ment 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:

JPM JPA Effect at yarn jump

– – Yarn jumps are registered and counted.

X – A cut follows a yarn jump.
X X 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.

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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.

“Don’t cut drum wrap” prevents loose pieces of yarn on ESPERO, ORION, POLAR, SMARO and
SPERO winder.

DWM DWA Don’t cut DW Effect at danger of drum wrap

– – – Drum wraps are registered and counted.

X – – Cut at drum wrap

Espero, Orion, Polar, Smaro and Spero: Wind-
X – X ing machine stops without cut.
Other machines: not available.
X X – Cut, textile alarm with SP blocking

Table 11-2

Fig. 11-17 Display of the group setting of the winding machine

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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 yarn (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 yarn (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 multi-
ple 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 opera-
tion 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 bob-
bin. 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 time-
consuming.

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In order to make this procedure of the splice control easier, the USTER® QUANTUM 3 splice classifi-
cation was introduced. During the measurement, the values are recorded and displayed as a scatter
plot in the classification matrix (Fig. 11-18). 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. 11-18 Classification matrix 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 meas-
uring 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“.

JPA
If the function JPA is turned on, a textile alarm is triggered for every JPM-cut which blocks the respec-
tive winding position

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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”.

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”.

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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 repeat-
edly, 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. De-
viations 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“.

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