Beruflich Dokumente
Kultur Dokumente
Made by:
Raisa Gupta (15)
Defected and Defect-free Fabric..
• What is a Fabric Defect?
A Fabric Defect is any abnormality in the Fabric that
hinders its acceptability by the consumer.
..Some Knitting Defects..
Measurement of Bias ..
Skew or Bias - Measure the skew
in three places spaced as widely
as possible along the length of the
fabric or along a minimum of 1
linear yard. If possible,
make no measurement closer to
the ends of the roll or piece of
fabric than 1 yard. Draw a line
perpendicular to the selvage
across the fabric from a point C
where the marked yarn or course
meets one selvage, meeting the
other selvage at point B. Measure
the distance between points A and
B or D and B, and B and C, as
shown in Fig. 2. Record the three
or more skew or bias
measurements. Calculate the
maximum skew or bias as a
percentage of the fabric width
using the equation:
"% Skew = Distance AB or DB x 100 /
width BC"
Measurement of Bowing..
Bow –
A straightedge is
placed across the
fabric between the
points at which a
marked filling yarn or
knitting course meets
the two selvages or
edges. The greatest
distance between the
straightedge and the
marked filling yarn or
course is measured
parallel to the
selvages (Fig. 1
Distance "D").
Different Causes of Fabric Barre..
Raw material,
Knitting and Yarn
consideration
What are the factors that
could lead to fabric defects?
Machine-Related Factors:
• Failure of spinning preparation to eliminate or minimize short
and long-term variation
• Failure of opening and cleaning machines to completely
eliminate contaminants and trash particles
• Failure of the mixing machinery to provide a homogenous blend
• Excessive machine stops particularly during spinning
• Excessive ends piecing during spinning preparation
• Poor maintenance and housekeeping
• Knitting-related defects
• Dyeing and Finishing-related defects
What are the factors that
could lead to fabric defects?
Material-Related Factors:
• Fiber contaminants
• Excessive neps and seedcoat fragments
• Excessive short fiber content
• Excessive trash content
• High variability between and within-mix
• Clusters of unfavorable fiber characteristics
• Weight variation
• Twist variation
• Excessive Hairiness
Some other Fabric Defects..
Small bits of
contaminants spun
into the yarn
White
specs
Synthetic fibre
contaminant
Pointers focussing on the Defected area..
Pointers focussing on the Defected area..
Factors Affecting Defects in Plain-Weft Knitted
Fabrics due to Knots of Spun Yarns..
• The knitting defect due to the knot is almost the knitting hole caused by
the end breakage in plain-weft knitting zone. The end breakage occurs
near the knot on the take-down side.
• The end breakage rate increases together with the increase of the depth
of stitch draw, the input tension, the take-down weight, the machine
gauge, the coefficient of yarn friction, the step length of cam, and the
machine speed. But the increase of the cam angle decreases the end
breakage rate.
Shade Variation and some Defect examples..
Present Scenario-
Inspection is done manually, ie., when a significant
amount of fabric is produced,the fabric roll is
removed from circular knitting machine and then
sent to an inspection frame.
Optimal Solution-
To automatically inspect fabric as it is being produced
and to encourage maintainence personnel to prevent
production of defects or to cahnge process
parameters automatically and consequently improve
fabric quality.
Fabric faults, their
Causes and
Solutions..
Varied defects are mentioned
here .Each defect can have
innumerable number of
reasons behind it’s
occurrence and there can be
many alternative ways to
correct the problem.
Precautions Taken to Minimize
Defects..
• Yarn mixing during feed into the machine should be
prevented.
• Needle and jack should be checked for defects.
• Yarn placement should be in the frame.
• Always check the fabric is not creased during passage
through breaking and squeeze roller ends.
• Follow bundling and shadesorting procedures
cautiously.
• Make sure the waste fluff nad lint does not mix up
with the garment.
• Keep checking from time to time that the machine is
working properly and the speed is as per requirements
Recent Advancement in
dealing with Fabric Defects..
• A novel approach is developed to identify fabric defects
through the integration of image processing techniques and
Neural Nets.
• In industrial setting, knitted fabric defects can be eliminated
or reduced by means of on-line monitoring system and
automatic defect detection devices.
• Morphological analysis: A system has been developed to
measure knitted fabric parameters using image analysis
techniques. This technique can be used to evaluate courses
per unit length, wales per unit length,fabric cover and weight
per unit area.
• Development of an Intelligent Fabric classification System:
The overall approach encompassed six steps: knitting fabric
samples, image capturing using a CCD camera, image
processing, binary image preparation as a preprocessor for
Neural Nets,image feature extraction and finally Neural Nets
classification.
Hardware Components used in
the Inspection Structure..
Flowchart of Defect
Segmentation..
On-line Fabric Defect Detection..
Circular Knitting Machine
Fabric Defect
Detection Scanning
for Circular Knitting..
• These designed defect scanners are known to be extremely accurate, self-cleaning
and with high resolutions through their unique mounting hardware systems.
• Through a system of choker and expander assemblies, a vertical air gap is created,
allowing RunStop scanning for maximum fabric-scanner interfacing.
• These hardware systems are easily adaptable to differing brands of knitting
machines and to varying production abilities of those machines
• .Various sizes of the infrared scanner facing are also easily adaptable to a variety of
machines, while infrared light is employed to eliminate ambient light interference.
Wire guarding of the scanner mount ensures protection against press-offs. Robust
scanner designs ensure durability in the harsh conditions of the mill environment.
• Fabric defect detection is the basic work of the System. With defect scanning,
circular knitting has been revolutionized, and has increased textile profits globally.
Defects and Mending at
RANA POLYCOT..
Some of the most common defects,mending strategies and
requirements in that industry:
• Incase a panel is curved from it’s path rather than being
a straight line,a latch needle is used to mend the side of
the panel and bring it in line with the initial garment
line.
• Fastening at the edges of the panels done by the SHIMA
SEIKI machine should follow a straight line,in case it does
not it needs to be mended.It is all done manually by the
latch needle.
• In case the machine stops workin properly during
construction and ruins the fabric,the panels are rejected
but in case of an urgency and with extra cash flow,it is
mended.
• While makin the rib and conjoining with the top,at
times,the hook leaves the yarn and a hollow is created.
My Industrial Visit Experience..
Defects found at RANA POLYCOT,MOHALI and the causes :
• While using the needle,the latch failed to cast off it’s
loop,takin one yarn after the other and putting extreme
pressure thus creating a defect.
• Torque of the comb at the sides got less thus the cloth
jumps from it’s place leading to a minor defect in the rib
structure.
• Machine speed increases at times,so does the take
down and so the stitch becomes tight and the cloth rips.
• A defect comes into picture when a double thread works
all through the stitching but suddenly it starts with
single.
• A fault may also occur because of the needle,when the
latch does not cast off properly and thus can’t be
mended.Needle shape gets distorted.
• High speed of the machine, more take down and
transfer speed,more roller speed,the inability of the
needle to make a proper loop can create defects.
Defects and Mending at
RANA POLYCOT..
• At times the fastening line left at the edges gets a reduction
from the boundary eg. From line 5 to 3 and thus needs
mending.
• At times the edge lock leaves the edge and the fabric starts
disentangling.This requires immediate hand-mending.
• During cable construction,there is a case where 3 up,3 down
technique is followed but suddenly the machine leaves the
area,mending comes to the rescue here.
• Sometimes,the stripe width of the striper varies all the
way.This needs serious mending.It is also a knitting fault.
• In some cases,the thread edges left at the corners get pulled
which distorts the entire garment.It needs to be pressed and
stretched and brought back to shape.Hurrieda nd harsh
action can ruin the cloth.
• At times fastening spacing goes berserk,if rectified,it follows
a loose-tight sequence.Gives the garment a shabby look.
Bibliography..
• RANA POLYCOT industry report
• www.matrixcontrols.com
• www.fibre2fashion.com
• http://158.132.122.156/itc/macau/defects/tsld003.htm
• www.saarczone.com
• www.apparelsearch.com
• www.highbeam.com
• www.encyclopedia.com
• www.resil.com
• www.ntcresearch.org
• www.iso.org
• www.trg.sagepub.com
• www.indiantextilejournal.com
• www.sitra.org
• www.taispk.com
..THANK YOU..