Uster Quantum 4.0 presents the unique combination of both capacitive and optical sensors in one. It’s the best of both worlds, for spinners. Two years after market introduction, industry feedback underlines the benefits of Uster’s new cross clearing and density detection functions.
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Making a choice between the two main technologies for yarn clearing is now a thing of the past. That’s because Uster’s latest Quantum 4.0 clearers offer both capacitive and optical sensors in a concept called Smart Duo. This innovation recognizes that each sensor option has its own special functionality – so using both together brings significant advantages in quality and profitability for spinners.
Cross clearing
The Smart Duo approach employs ‘cross clearing,’ utilizing both capacitive and optical sensors. The capacitive signal targets small yarn faults, ensuring detection of dense thick areas with increased mass due to more fibers. On the other hand, the optical sensor detects minor diameter increases, particularly in visually larger yarn occurrences. To optimize detection for both compact and fluffy events, the signals are combined in series. This cross-clearing function employs a second clearing limit as a backup after the basic parameters, enhancing fault detection. For instance, if a thick area isn’t flagged by capacitive limits, the optical settings serve as a check. This ensures identification of thick and fluffy events missed by the capacitive sensor alone. Cross clearing events (X) also prove valuable for indicating spinning conditions, aiding in maintenance, and managing fiber accumulation in creels or drafting zones.
No compromises for better fabric quality
A spinner in India producing 100% combed cotton yarn (Ne 30) for knitted fabrics demonstrated the benefit of cross clearing in a practical example. The goal was to improve fabric quality by reducing the remaining thick places, while maintaining the same level of clearer cuts. To ensure an independent assessment of the fabric samples, an Indian textile institute conducted the inspection and comparison. During the tests, the team maintained the cross clearing setting at ‘medium’ and slightly adjusted the NSL setting to account for the additional X-cuts. In conclusion, they cleared both articles with 92.6 cuts/100 km for the NSL T, considering the X-cuts, and 92.5 cuts/100 km for the NSL T without activating cross clearing. The cross clearing function demonstrated improved fabric quality without the need for additional cuts. The Uster Smart Duo was able to ensure better quality without increased production costs.
Density detection
Density measurement is unique in the market, as a highlight feature introduced by the Smart Duo function of the Quantum 4.0 clearer. It involves two separate measurements: the density channel (D) is active after the splice over a defined reference length; in addition to this temporary density measurement, a continuous density (CD) measurement takes place. Different densities can be caused by different twist levels in the yarn. Other factors could be a mixture of compact and non-compact yarn or irregularities in compacting levels, while different yarn types and materials also have different densities. The density measurement function also prevents yarn issues caused by malfunctioning of the compacting device.
Saving a ton of yarn
In another practical example, a customer in China discovered that one of its ring spinning machines was producing high twist yarn. Some high twist yarns were mixed with regular yarns on the winding machine, with the result that 1.21 tons of yarn was contaminated and rendered unusable.
It is impossible to differentiate between yarns of different twist levels by eyesight at the ring frame stage. And until the launch of Uster Quantum 4.0 there was no way to separate yarn with different twists at the winding stage. Thanks to the density detection function, the spinner saved 1.08 tons of yarn that would otherwise have been waste. By installing the new generation of Uster yarn clearers the mill was able to rewind the yarn to separate the high twist element.
Innovated for the major challenges
Quantum 4.0 is the efficient yarn quality assurance system with Smart Clearing Technology for both standard and special applications. The new Smart Duo technology further enhances the accepted standards of Yarn Body, Dense area, and Smart limits. Numerous easy-to-use functions cover basic clearing, Smart Duo clearing – including cross clearing and density detection – as well as contamination clearing and special applications. Uster’s latest yarn clearing innovations provide maximum flexibility, security and prevention for today’s market challenges in spinning mills.
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