UQ3 Quick Reference Guide For Self-Education PDF

USTER® QUANTUM 3
SHORT APPLICATION
HANDBOOK
Quick Reference Guide

for self-education
THE YARN QUALITY ASSURANCE SYSTEM
V1.2
May 2011
316 050-05020
Quick Reference Guide for self-education
1 Main features of the USTER® QUANTUM 3 ............................................................................. 3
1.1 Introduction ..................................................................................................................................... 3

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1.2 Structure of the USTER QUANTUM 3 ......................................................................................... 3
2 Setting a smart clearing limit for disturbing thick places (NSL) and thin places (T)............ 4
2.1 Introduction ..................................................................................................................................... 4

2.2 Definition of the yarn body ............................................................................................................ 4
2.3 Development of the yarn body / Example of Ne 30/1, 100% cotton yarn .................................. 5
2.4 Examples of various yarn bodies ................................................................................................. 6
2.5 Interpretation of the yarn body ..................................................................................................... 7
2.6 Classification matrix ...................................................................................................................... 8
2.7 Setting a smart clearing limit for disturbing thick places (NSL) and thin places (T) ............. 8
3 Setting the detection of Periodic Faults (PF) / Option Q Data ............................................. 11
3.1 Introduction ................................................................................................................................... 11

3.2 Setting for Periodic Faults (PF) ................................................................................................... 11
4 Setting a smart clearing limit for dark foreign matter (FD) / Option .................................... 13
4.1 Introduction ................................................................................................................................... 13

4.2 Dense Area .................................................................................................................................... 13
4.2.1 Examples of various dense areas .................................................................................................. 14
4.3 Setting a smart clearing limit for dark foreign matter (FD) ...................................................... 15
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4.4 Classification matrix of foreign matter with the USTER QUANTUM 3 .................................. 17
5 Setting a clearing limit for foreign matter (FD) with Vegetable Clearing (VEG) ................. 17
5.1 Introduction ................................................................................................................................... 17

5.2 Dense area for vegetable matter (VEG) ...................................................................................... 17
6 Setting a smart clearing limit for Polypropylene Clearing (PP) / Option ............................ 20
6.1 Introduction ................................................................................................................................... 20

6.2 Scatter plot .................................................................................................................................... 21
6.2.1 Examples of various scatter plots ................................................................................................... 22
6.3 Setting a smart clearing for polypropylene fibers .................................................................... 23
7 Setting the detection of count deviations (C and CC settings) ........................................... 25
7.1 Introduction ................................................................................................................................... 25

7.2 Definition of the yarn body for count variations (C and CC faults) ......................................... 26
7.2.1 Scatter plot of yarn count monitoring at start-up / Practical example ............................................. 27
7.3 Scatter plot of count deviations / Practical example ................................................................ 28
7.4 Setting a smart clearing limit for yarn count monitoring (CC) ................................................ 29
USTER® QUANTUM 3 1 (46)

8 Setting a clearing limit for Splice Clearing (Jm /Jp)............................................................. 31
8.1 Introduction ................................................................................................................................... 31

8.2 Scatter plot of splices .................................................................................................................. 31
8.2.1 Examples of various scatter plots for splices. ................................................................................ 33
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8.3 Splice classification of the USTER QUANTUM 3 ..................................................................... 33
8.3.1 Setting a smart clearing limit for splices (Jp/Jm) ............................................................................ 34
9 Quality parameters of a yarn / Option Q-Data ...................................................................... 35
9.1 Introduction ................................................................................................................................... 35

9.2 Setting of quality characteristics: Yarn evenness (CV) ............................................................ 37
9.3 Setting of quality characteristics: Hairiness (H) ....................................................................... 38
9.4 Setting of quality characteristics: Imperfections (IP) ............................................................... 39
9.5 Setting of quality characteristics: Class Alarm ......................................................................... 40
9.6 Setting of quality characteristics: Tailored Classes (Option Advanced Classes) ................. 41
10 Collecting defects .................................................................................................................. 42
10.1 Introduction ................................................................................................................................... 42

10.2 Event display by the red light at the sensor (iMH-LED)............................................................ 42
10.3 Yarn fault boards .......................................................................................................................... 43
11 Features of the USTER® QUANTUM 3 and options .............................................................. 45
11.1 Table of standard features and options ..................................................................................... 45

11.2 Features and sensors................................................................................................................... 46
© 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.
veronesi\TT\Schulung Dokumente\On-Line\Garnreiniger\UQ3\Short Application englisch\Quick Reference Guide for self-education
2 (46) USTER® QUANTUM 3

1 Main features of the USTER® QUANTUM 3

1.1 Introduction
The USTER® QUANTUM 3 is a yarn clearing system for winding machines and 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 simpli-
fying 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 paper as a quick reference guide for the setting of the most important features
of the USTER® QUANTUM 3. This paper is targeted on 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 mod-
ern technology, the user will be able to deliver significantly better yarn quality and post spinning per-
formance while most likely maintaining productivity.
1.2 Structure of the USTER® QUANTUM 3
As we mentıoned before, 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 distinguish colors and separates foreign matter into two sepa-
rate 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. 1-1 New features of USTER QUANTUM 3

2 Setting a smart clearing limit for disturbing thick places (NSL) and
thin places (T)
2.1 Introduction
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:
• N – faults: thick places from 0,2 cm to < 1 cm → very short thick places (N fault)
• S – faults: thick places from 1 cm to < 8 cm → short thick places (S fault)
• L – faults: thick places as of 8 cm to < 200 cm → long thick places (L fault)
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 fibers in the cross-section as a result of a non-optimal
drawing process.
2.2 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 expe-
rience 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.
In Fig. 2-1, the dark green area represents the yarn body and the light green area the yarn body varia-
tions, 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. 2-1, 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 clearing limits are shown with red color (in Fig. 2-1, top right cor-
ner, 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. 2-1 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.
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 lowered.
2.3 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. 2-2 Yarn body after 4,6 km Fig. 2-3 Yarn body after 49,2 km Fig. 2-4 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 cal-
culations. But already after 30 km of running the variation has stabilized and the optimization process
for the clearing limits can start. There is practically no difference anymore between Fig. 2-3 and Fig.
2-4.
If we calculate the duration of the above mentioned start-up for a link system with 23 winding posi-
tions 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
2.4 Examples of various yarn bodies
Fig. 2-5 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.
Fig. 2-6 Yarn body, polyester 100%, Nec 40, 523 km, knitting, (left), 382 km weaving, (right), clearer C15

Fig. 2-7 Yarn body, cotton 100%, carded, knitting, 413 km (left), 553 km (right), count Nec 40, clearer C15
Fig. 2-8 Yarn body, Nec 40, 35% cotton/65% viscose, weaving, 353 km (left), Nec 40, 55% cotton / 45%
polyester, weaving, 361 km (right), clearer C15
2.5 Interpretation of the yarn body
The Fig. 2-5 to Fig. 2-8 demonstrates 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 follow-
ing:
• 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 fiber 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 opti-
mize 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.
2.6 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. Fig. 2-9, shows the classification
matrix of thick and thin places. With the help of new extended classes, the user can monitor and con-
trol critical (e.g. short and fine) defects which often determine the fabric appearance.
Fig. 2-9 Classification matrix
2.7 Setting a smart clearing limit for disturbing thick places (NSL) and thin
places (T)
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 always
follow the body and avoid unintended opening of settings to prevent disturbing thick and thin places
from getting to the final fabric. It also at the same prevents entering into the yarn body and prevent
removal of defects that don't add value to the yarn but simply create splices which then could poten-
tially break in weaving. In other words the default smart limit based on the yarn body is a nearly opti-
mal clearing limit from a quality point of view (Fig. 2-10).

Pressing key presents

• The yarn body.
• Scatter plot of the cut faults and
remaining events.
• Number of expected 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. 2-10 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 our 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. 2-12 shows the selection of the optimum clearing curve for thick places. For a few seconds or
minutes the yarn runs with a re-defined 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 or by manual adjustment. The setting can be fixed by pressing
the “confirm” button.
The setting of USTER® QUANTUM 3 can be done simply in one step:
Fig. 2-11 Start with standard setting Fig. 2-12 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 start-
ing 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.
Of course all settings recommended by smart limit can also be altered manually. Even in this case the
new cut forecast is calculated after pressing the viewing button once.
=
The new setting point proposals
= 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. 2-13 Proposed setting is a starting point for optimization
The user can set a smart clearing limit for thin places (T) in a similar way. The Smart Limit function
proposes a starting point for the clearing limits based on the yarn body and also provides a cut fore-
cast to facilitate faster setup of clearing limits. The setting of USTER® QUANTUM 3 can be done
simply in one step:
Fig. 2-14 Start with standard setting Fig. 2-15 Only one step / Press smart limit button
and get a proposed setting including the
cut forecast based on the yarn running

3 Setting the detection of Periodic Faults (PF) / Option Q Data

3.1 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. 3-1.
Fig. 3-1 Periodic fault in cotton yarn resulting in a moiré
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 adjustable clearing limits. With the USTER® QUANTUM 3 such
periodicities can be detected with the Periodic Fault (PF) feature. 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 wave-
lengths simultaneously.
3.2 Setting for Periodic Faults (PF)
The periodic yarn faults are thick and thin places, which always occur with the same distance from
each other. The thick places which are caused 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
After reaching the given number of faults ("number of periods"), a cut follows or a PF-alarm is trig-
gered.

Fig. 3-2 PF settings for detecting periodic defects Fig. 3-3 Disturbing defects (so-called periodic
defects)
When the setting of the period regularity is 100%, then the channel will detect only one type of fault
which is truly periodic and occurs after a certain distance (Fig. 3-3). A setting of 100% means the pe-
riodicity is absolute. However, on the winding machine a defect is never strictly periodic as already
mentioned due to the varying yarn speed.
Fig. 3-4 PF settings for detecting periodic defects
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 in
the sensitivity settings. Furthermore, it is recommended to produce a taper board with the defective
yarn for a visual evaluation of the defect or use the USTER® TESTER to evaluate the spectrogram.

4 Setting a smart clearing limit for dark foreign matter (FD) / Option
4.1 Introduction
Foreign fibers are one of the major problems in spinning mills. Fabrics containing foreign fibers cannot
be dyed homogeneously, and these fibers can cause many quality problems, especially after finish-
ing. Many foreign fiber problems are detected only after finishing, and the spinner is ultimately held
responsible for the damage. 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.
The following is a collection of experience with foreign matter removal systems prior and after the
card.
Fig. 4-1 show separated foreign material in cotton.
Fig. 4-1 Separated foreign material in cotton Fig. 4-2 Inorganic fibers in card sliver
In Fig. 4-2 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 matter. The plastic
fiber cluster (Fig. 4-2) will result in foreign fibers in yarns.
4.2 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. 4-3). 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 events for the For-
eign 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. Having detected
all the defects, the USTER® QUANTUM 3 splits the foreign matter into two pools, disturbing colored
foreign fibers and mostly non disturbing vegetable foreign matter (see chapter 5). Separate limits for
foreign fiber and vegetable matter can be defined.
Fig. 4-3, shows a dense area with yarn faults as seen by the USTER® QUANTUM 3, with all the fre-
quent remaining events recorded in the yarn (blue dots), and with the marked area of the dense area
(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. 4-3 Display of the dense area and the scatter plot for foreign matter, 63,4 cuts per 100 km
4.2.1 Examples of various dense areas
Fig. 4-4 Display of the dense area and the scatter plot for foreign matter. Left: 1208,1 km / Right 1627,8 km

Fig. 4-5 Display of the dense area and the scatter plot for foreign matter. Left: 1293,5 km / Right: 466,8 km
4.3 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. 4-6).
area and the events will appear. In order to see the dense area, the user should press the dense area
key (Fig. 4-7). 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. 4-8).

• The dense area.
• Scatter plot of the cut faults
and remaining events.
• Number of expected fault /
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. 4-6 Display of the dense area, 66,4 cuts per 100 km

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. 4-7, Fig. 4-8):
Fig. 4-7 Setting page for FD manual setting or Fig. 4-8 Display of dense area
setting by smart limits available
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. 4-9). 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 recom-
mended 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.
= Smart Limit 1 step less sensitive.
= Smart Limit 1 step more sensitive.
= Show dense area and

scatter plot
= confirm and activate optimized

clearing limit.
= cancel all modifications

4.4 Classification matrix of foreign matter with the USTER® QUANTUM 3
Uster Technologies has developed a classification matrix for foreign fibers and vegetable matters. Fig.
4-10 shows the structure of the classification matrix for foreign fibers, which represents the reflec-
tance (in %) and length (in cm). The reflectance corresponds to the visibility of a fault.
Fig. 4-10 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 plac-
es and thin places.
5 Setting a clearing limit for foreign matter (FD) with Vegetable

Clearing (VEG)
5.1 Introduction
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 in
combination with the new C-sensor and also enables the classification of vegetables separately. The
USTER® QUANTUM 3 smartly splits the foreign matter into two populations, disturbing colored inor-
ganic foreign fibers and non disturbing vegetable foreign matter. Separate limits for foreign fibers and
vegetable matter can be defined.
5.2 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 4. 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 events for the vegetable matter.
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.

area and the significant foreign fibers will appear.
Fig. 5-1 shows a dense area for inorganic foreign matter with vegetable clearing and Fig. 5-2 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. 5-1 Display of the dense area and the scatter Fig. 5-2 Display of the dense area and the scatter
plot for foreign matter (foreign matter only) plot for vegetable matter only
As shown in Fig. 5-3, two separate limits for foreign 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. 5-3 Separate limits for foreign matter fibers and vegetable matter

Fig. 5-4 shows how the foreign matter can be separated into inorganic foreign fibers and vegetable
matter.
Scatter plot containing

foreign matter and vegeta-
ble matter (FD Clearing)
Scatter plot containing only Scatter plot containing only

foreign fibers (VEG Clearing) vegetable matter (VEG Clearing)
Matrix of foreign matter showing clearing curve for foreign Matrix of vegetable matter showing both clearing curves
matter (VEG Clearing) for foreign and vegetable matter (VEG Clearing)
Fig. 5-4 Separation of foreign and vegetable matter

6 Setting a smart clearing limit for Polypropylene Clearing (PP) /

Option
6.1 Introduction
With the foreign fiber measuring method, only colored foreign fibers can be detected in a yarn. For-
eign fibers consisting of polypropylene, however, are often white or without any color and, are there-
fore, 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. 6-1). Polypropylene is used as a package material for cotton bales and as such the source of
the contamination of cotton.
Fig. 6-1 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. 6-3) and after dyeing (Fig. 6-4).
There are more and more complaints in the textile chain because of polypropylene fibers remaining in
the fabric because the damages are enormous since many polypropylene fibers can only be detected
in finishing.
Fig. 6-2 Examples of polypropylene

fibers / Optical microscope pho-
tography

Fig. 6-3 Polypropylene fiber in a knitted fabric before dyeing
Fig. 6-4 Polypropylene fibers in a knitted fabric after dyeing
The fact that the PP fibers do not absorb dyestuff used for cotton makes it hard for spinning mills to
recognize them.
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 considera-
ble 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 proba-
bility that polypropylene fibers contaminate the cotton.
The USTER® QUANTUM 3 has a new, smart polypropylene (PP) clearing system. The clearer set-
tings 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. Fur-
ther, the new USTER® QUANTUM 3 polypropylene clearing has no count, length or speed re-
strictions. 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 polypropyl-
ene clearing, the user can detect very fine and short polypropylene fibers.
6.2 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 polypropylene faults length in cm. Fig. 6-5 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).

The scatter plots are used to visualize the optimum clearing limits for both the Splice Clearing (Jp/Jm)
and polypropylene (PP) and for such events the graphical display of a scatter plot matches the de-
mands of the customer’s best. The scatter plot for polypropylene (PP) represents the classified splice
events.
Fig. 6-5 Frequent and seldom-occurring yarn faults. Measured yarn length: 2298 km
The scatter plot also depends on the raw material. If a yarn produced from cotton having a lot of poly-
propylene fibers, the scatter plot will be denser with many dots, and a high number of cuts can be
expected.
6.2.1 Examples of various scatter plots
Fig. 6-6 Yarn Ne 40, 100% cotton, combed, knit- Fig. 6-7 Yarn Ne 60, 100% cotton, combed,
ting, 1438 km. Low amount of PP fibers: weaving, 1952 km. High amount of PP
1,7 PP fibers per 100 km fibers: 7,2 PP fibers per 100 km

Fig. 6-8 Yarn Ne 40, 100% cotton, combed, com- Fig. 6-9 Yarn Ne 60, 100% cotton, combed,
pact, 2298 km. Low amount of PP fibers: compact, weaving, 2254 km. High
3,2 PP fibers per 100 km amount of PP fibers: 6,6 PP fibers per
100 km
6.3 Setting a smart clearing 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
dying of the finished cloth because the polypropylene fiber doesn’t 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 de-
fects 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 tech-
nological 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. 6-10). Besides the scatter plot, the cut faults and remaining events and the number of ex-
pected fault cuts per 100 km can be seen on the screen. The used setting limits will appear directly on
the same setting page (Fig. 6-10) or on the display page automatically.


• Scatter plot of the cut faults and re-
maining events.
• Number of expected cuts / 100 km.
Clearing limit
Grey dots = remaining events.
= Proposes the starting point

for the clearing limits based
on the scatter plot.
As soon as the button at the setting page is pressed, the yarn body and the expected cut figure per
100 km is displayed on the same setting page (Fig. 6-10).
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 cal-
culated setting point values appear in blue color. Every time this key is pressed, the limit moves fur-
ther 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.
= Smart Limit 1 step less sensitive.
= Smart Limit 1 step more sensitive.
= Show scatter plot

clearing limit.

7 Setting the detection of count deviations (C and CC settings)

7.1 Introduction
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. 7-1 shows the possibilities for yarn fault monitoring, if the fault channels N, S, L, T, C and CC are
active.
Fig. 7-1 Clearing limits N, S, L, T, Cp, Cm, CCp and CCm
The C-channel monitors the yarn count in the start-up phase after the splicing process. After the start-
up phase, the C-channel is not active anymore. As already known from USTER® QUANTUM 2, the C-
channel 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. 7-2 Display of C setting, only one reference Fig. 7-3 Display of CC setting. Smart limits availa-
length to be set ble for length classes from 2 – 12 meters.

7.2 Definition of the yarn body for count 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 accord-
ing 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 refer-
ences. Based on the references, the operator can identify changes. The yarn body becomes always
wider in the direction of the short reference lengths, 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 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 C is composed of two parts:

• Dark green line representing the real yarn body.
• Light green line representing yarn body variations.
Fig. 7-4 Yarn body display for C, defined from 2 Fig. 7-5 Yarn body display for medium and long-
to 12 m term variations (CC faults), defined from
2 to 12 m
The vertical scale represents the yarn mass or diameter increase and decrease, and the horizontal
axis represents the reference 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.

7.2.1 Scatter plot of yarn count monitoring at start-up / Practical example
Fig. 7-6 Yarn Ne 40, cotton 100%, combed, compact, capacitive sensor, 1010 km. Short reference length
(2 m) adjustment§. It is recommended changing the reference length to 6 m or 8 m
Fig. 7-7 Yarn Ne 24, cotton 100%, carded, Fig. 7-8 Yarn Ne 24, cotton 100%, carded, capaci-
capacitive sensor, 10035.2 km. tive sensor, 3067.9 km.
Open settings, reference length is 10 m. Close settings, reference length is 10 m.

7.3 Scatter plot of count deviations / Practical example
Fig. 7-9 Frequent medium-term deviation of the count. Analysis of the spinning process required.
Fig. 7-10 Yarn Ne 40, cotton 100%, carded, knit- Fig. 7-11 Yarn Ne 32, cotton 100%, carded, knit-
ting, capacitive sensor, 1582 km. ting, capacitive sensor, 3496 km, wider
Low number of count deviations within yarn body.
the range of 2 to 12 m, 0,8 + 0,2 = 1,0 High number of count deviations between
per 100 km. 2 and 12 m, 3,4 + 1,5 = 4,9 per 100 km.

Fig. 7-12 Yarn Ne 12, cotton 100%, carded, weaving, Fig. 7-13 Yarn Ne 16, cotton 100%, carded, weav-
capacitive sensor, 771 km. High number of ing, optical sensor, 492 km. Low number
count deviations within the range of 2 to 12 of count deviations within the range of 2 to
m, 8,3 + 2,6 = 10,9 per 100 km. 12 m, 4,1 + 2,0 = 6,1 per 100 m.
7.4 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 lines between the set points represent the clearing limit. The setting points are:
• 2 Set points: CCp +% at 2 m and 12 m
• 2 Set points CCm -% at 2 m and 12 m.
Fig. 7-14 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.

• The yarn body.
• Scatter plot of the cut faults.
• Number of expected fault cuts /
100 km.
Clearing limit
=Yarn body variation

=Yarn body
= Proposes the starting point for

the clearing limits based on the yarn body.

By pressing Smart Limit function a proposed starting point for the CC settings will be selected. Ac-
cording to the need of the customer this proposal can be accepted or modified with the smart limit
function or manually.
Fig. 7-15 Start with standard setting. Press Smart Fig. 7-16 Only one step / Display of CC setting,
Limit key 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 opti-
mize 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 recom-
mended 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.
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.
=
= Smart Limit 1, step less sensi-
tive.
= Smart Limit 1, step more sensi-
tive.
= Show yarn body and scat-
ter plot
clearing limit.

8 Setting a clearing limit for Splice Clearing (Jm /Jp)

8.1 Introduction
A splice, also called yarn joint, has the purpose to join two ends of a yarn as a result of yarn fault re-
moval 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 auto-
matic splicing device. 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 pro-
duce 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.
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 ring-spun yarn (Ne 30) 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.
8.2 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 increase and decrease, of
a splice and the horizontal axis represents the splice length in cm. Fig. 8-2 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 mini-
mum admissible dimension.
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 cus-
tomers best. The scatter plot for Splice Clearing (Jp/Jm) represents the classified splices. The
USTER® QUANTUM 3 classifies the thickest (Jp, Fig. 8-1, red circle) and thinnest (Jm, Fig. 8-1, 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, plus).

Fig. 8-1 Splice distribution. Measured yarn length: 216 km
In the display main menu, it is possible to display either scatter plot of splices alone (Fig. 8-2) or to-
gether with the scatter plot of disturbing thick and thick places (NSLT) (Fig. 8-3). Fig. 8-3 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. 8-2 Scatter plot of splices with the clearing Fig. 8-3 Scatter plot of splices and thick/thin
curves for thick/thin places and splices places together

8.2.1 Examples of various scatter plots for splices.
Fig. 8-4 Splice clearing curve identical with NSLT Fig. 8-5 Splice clearing curve identical with
clearing curve NSLT clearing curve, but far away from
the splice populations
Fig. 8-6 Splice clearing curve narrower than Fig. 8-7 Splice clearing curve narrower than
NSLT clearing curve NSLT clearing curve, but still far away
from the splice populations
Splices beyond the clearing curves (red dots) have to be repeated.
8.3 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. 8-8).

Fig. 8-8 Display of splices (left) and splice classification on the same screen with both clearing limits (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.
8.3.1 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. 8-9). 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. 8-9). It is recommended to have at least 100 splices before
making any fine tuning in the splice clearings settings.
• Scatter plot of the cut faults and re-

maining events.
• Number of expected cuts / 100 km
Clearing limit

Green dots = remaining events
Fig. 8-9 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). High quality customers 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 clear-
ing curve above the NSL thick places clearing curve (less sensitive setting, Fig. 8-9). 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. 8-9).
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. 8-9), blue circle):

For capacitive clearers: 80%
For optical clearers: 60%
9 Quality parameters of a yarn / Option Q-Data

9.1 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 wind-
ing 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. 9-1 Frequent yarn faults and seldom-occurring yarn Fig. 9-2 Disturbing yarn faults were
faults 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 pro-
duction costs, yarn manufacturers have to optimize the individual production stages at shorter inter-
vals 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 pa-
rameters during the production.
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. 9-3 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 pro-
duction. The analysis of the single value makes it possible to carry out countermeasures without any
time delay.

9.2 Setting of quality characteristics: Yarn evenness (CV)
The evenness CVm belongs to the most important quality characteristics of yarns. With this setting
the reference length, the mean value per group and per winding position and the alarm limits for the
winding positions can be set. The coefficient of variation CV is a well-known value for the determina-
tion 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 measure-
ments:
• 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.
The USTER® QUANTUM 3 determines the overall irregularity by calculating the coefficient of variation
value CV according to the laws of statistics. With this value, it is possible to determine small differ-
ences with respect to mass variations or diameter.
Fig. 9-4 Setting for yarn evenness limits (CV) Fig. 9-5 Display of the yarn evenness (CV) value
Recommendations:
In general, below mentioned limits can be given as recommendations for CV limits:
CV limits: +20% and -16% of the mean value for the chosen evaluation length for spindle (standard
value is per 100 m). For optical clearers the correlation to the well-known USTER® TESTER is not
given, due to the different sensor principle. But still it can be used for the identification of outlier bob-
bins.

9.3 Setting of quality characteristics: Hairiness (H)
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 dis-
turbing 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 de-
viate 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. There-
fore, variations of the quality characteristics of conventional yarns from bobbin to bobbin have be-
come more disturbing than several years ago. This is also valid for the hairiness.
The USTER® QUANTUM 3 gives also the results of the hairiness per winding position as well as the
hairiness mean value of the group and the absolute alarm limit for the hairiness alarm.
Fig. 9-6 Setting for hairiness limits (H) Fig. 9-7 Display of the hairiness value
Recommendations:
In general, below mentioned limits can be given as recommendation for Hairiness:
Hairiness MV +1.0 / -1.0 (standard value is per 400 m)
Hairiness values are measured with the optical sensor F30 only.

9.4 Setting of quality characteristics: Imperfections (IP)
"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.
Imperfections are divided in three fault groups and four classes. This can be seen in Table 9-1.
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 9-1 Imperfections, fault groups and classes
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 bobbins has to be determined. The mean value indi-
cates 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. 9-8 Setting of the imperfection limits Fig. 9-9 Display of the imperfection values

9.5 Setting of quality characteristics: Class Alarm
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.
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 laborato-
ry. Seldom-occurring yarn faults are detected, assessed and classified within the well-known CLAS-
SIMAT matrix according to length and mass deviations.
This provides the user with complete information on the yarn quality and allows him to make a fore-
cast 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 require-
ment 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 100%, long
thick places with a mass or diameter increase of at least 45% and thin places with a mass or diameter
decrease of at least –30% are classified within the CLASSIMAT matrix in 23 thick and thin place clas-
ses. This allows the user to quickly identify any outlier winding positions. The CLASSIMAT matrix is
shown in the following figure.
Fig. 9-10 Setting of class alarm

9.6 Setting of quality characteristics: Tailored Classes (Option Advanced Classes)
The tailored classes offer the possibility to define customer classes or group classes together for spe-
cial 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. The settings can be done by defining sensi-
tivity 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. The tailored
class will be shown in the classification matrix of the related clearing function.
With the red light of the sensor it is possible to inspect yarn faults and foreign fibers within the custom-
ized class.
Fig. 9-11 Setting of the tailored classes
The tailored class will be shown in the classification matrix of the related clearing function (Fig. 9-12,
right side).
Fig. 9-12 Classification matrix at the Control Unit (at the “Displays” main menu)

10 Collecting defects
10.1 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.
10.2 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
• 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 wind-
ing positions.
When the programmed cut occurs:

• the winding position stops
• iMH LED flashes according to the selection
• red winding position lamp lights up continuously
• the winding position will start after confirming the stop.
The user should enter the range and cut type for the 3 display variants. These are:

Fig. 10-1 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. 10-1, right), the yarn faults / cuts are also displayed showing the size / intensi-
ty in % and length in mm, as well as their classification. The events which should be displayed have to
be selected in the Configuration Menu. The selected events are displayed with date, time and winding
position information (Fig. 10-2, right).
Fig. 10-2 Configuration menu (left) and Event Reports menu (right)
10.3 Yarn fault boards
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.

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 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 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
®
Fig. 10-3 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.

11 Features of the USTER® QUANTUM 3 and options

11.1 Table of standard features and options
Table 11-1 shows the individual standards features and the options.
OPTIONS FEATURES COMMENTS
Basic Yarn Body (N, S, L, T, CC) Visualization of the yarn characteristics

clearing Smart limits (N, S, L, T, CC) A proposed starting point for clearing limits
Visualization of the thick and thin places, count deviations and splic-
Scatter plot (N, S, L, T, C, CC, J)
es.
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
Foreign Dense Area (FD,VEG) Identification of range where foreign fibers are located
matter
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
Polypro- Smart limit (PP) A proposed starting point for polypropylene clearing limit
pylene
fibers Visualization of polypropylene fibers
Scatter plot (PP)
(Option)
Q-Data Evenness (CV) Determination of the yarn evenness

(Option) Imperfections Determination of the frequent thick places, thin places and neps
Basic on-line classification (NSLT, Classification of disturbing thick and thin places, foreign fibers,
FD, J and VEG) splices and vegetables
Triggering of alarm if the number of disturbing faults has exceed the
Class alarms
selected number of faults
Periodic Faults (PF) Detection of periodic faults
Hairiness Absolute hairiness measurement Determination of the hairiness value

(Option) Exception spindle detection Recognition of spindles with excessive hairiness
Expert Access to the data output for Expert System and centralized data
Expert collection and reporting
(Option)
Advanced Extended Classes Classification of additional classes in NSLT, F, VEG

Classifica-
tion Tailored classes Classes can be selected by customers
(Option)

OPTIONS FEATURES COMMENTS
Lab On- Software pack consists of Hairiness, Advanced Classification and

line (Op- Software pack Expert
tion)
Table 11-1 Features of Basic Clearing and options
11.2 Features and sensors
Table 11-2 below describes what type of USTER® QUANTUM 3 sensor for each measuring head is
appropriate for which kind of application.
®
USTER QUANTUM 3 SENSORS
Capacitive Capacitive Capacitive Capacitive Optical Optical

MEASURING HEAD TYPES
C15 C20 C15 F30 C20 F30 O30 O30 F30
BASIC X X X X X X
FOREIGN MATTER
--- --- X X --- X
(Option)
VEGETABLE (Option) --- --- X X --- ---

POLYPROPYLENE
--- --- O* O* --- ---
FEATURES
(Option)
Q-DATA (Option) O O X X O X
HAIRINESS (Option) --- --- O O --- O
®
USTER QUANTUM
EXPERT 3
O O O O O O
ADVANCED CLASSI-
FICATION (Option)
O O O O O O
LAB ONLINE (Option) --- --- O O --- O

®
Table 11-2 The USTER QUANTUM 3 sensors and options
Key:
X This feature is included in this version of the sensor
O Product Option Key (POK) is needed to have access to the feature mentioned in the header of this col-
umn
O* Hardware upgrade required in the Central Clearing Unit 6 (CCU6) to have access to the feature
--- Not available with this iMH type

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 461 040-05022 Printed in Switzerland © Copyright 2011 Uster Technologies AG

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USTER® QUANTUM 3

Quick Reference Guide

THE YARN QUALITY ASSURANCE SYSTEM

1 Main features of the USTER® QUANTUM 3 ............................................................................. 3

1.1 Introduction ..................................................................................................................................... 3

2.1 Introduction ..................................................................................................................................... 4

3 Setting the detection of Periodic Faults (PF) / Option Q Data ............................................. 11

3.1 Introduction ................................................................................................................................... 11

4.1 Introduction ................................................................................................................................... 13

5.1 Introduction ................................................................................................................................... 17

6.1 Introduction ................................................................................................................................... 20

7 Setting the detection of count deviations (C and CC settings) ........................................... 25

7.1 Introduction ................................................................................................................................... 25

USTER® QUANTUM 3 1 (46)

8 Setting a clearing limit for Splice Clearing (Jm /Jp)............................................................. 31

8.1 Introduction ................................................................................................................................... 31

9 Quality parameters of a yarn / Option Q-Data ...................................................................... 35

9.1 Introduction ................................................................................................................................... 35

10 Collecting defects .................................................................................................................. 42

10.1 Introduction ................................................................................................................................... 42

11 Features of the USTER® QUANTUM 3 and options .............................................................. 45

11.1 Table of standard features and options ..................................................................................... 45

© Copyright 2010 by Uster Technologies AG. All rights reserved.

veronesi\TT\Schulung Dokumente\On-Line\Garnreiniger\UQ3\Short Application englisch\Quick Reference Guide for self-education

2 (46) USTER® QUANTUM 3

1 Main features of the USTER® QUANTUM 3

1.2 Structure of the USTER® QUANTUM 3

USTER® QUANTUM 3 3 (46)

2.2 Definition of the yarn body

The yarn body is composed of two parts:

4 (46) USTER® QUANTUM 3

Area of the disturbing faults

Area of the yarn body

Area of the disturbing faults

USTER® QUANTUM 3 5 (46)

2.4 Examples of various yarn bodies

6 (46) USTER® QUANTUM 3

2.5 Interpretation of the yarn body

USTER® QUANTUM 3 7 (46)

2.6 Classification matrix

Fig. 2-9 Classification matrix

8 (46) USTER® QUANTUM 3

Pressing key presents

Red dots = cut yarn faults.

= Proposes the starting

The setting of USTER® QUANTUM 3 can be done simply in one step:

USTER® QUANTUM 3 9 (46)

= Smart Limit 1 step less

= Smart Limit 1 step more

= Show yarn body and

= confirm and activate

= Cancel all modifications

Fig. 2-13 Proposed setting is a starting point for optimization

10 (46) USTER® QUANTUM 3

3 Setting the detection of Periodic Faults (PF) / Option Q Data

Fig. 3-1 Periodic fault in cotton yarn resulting in a moiré

3.2 Setting for Periodic Faults (PF)

The recommended setting for FP (Periodic Faults) is:

USTER® QUANTUM 3 11 (46)

Fig. 3-4 PF settings for detecting periodic defects

12 (46) USTER® QUANTUM 3

Fig. 4-1 show separated foreign material in cotton.

4.2 Dense Area