870ex 06 Engls 191201

VORTEX 870 EX
Yarn Quality Control

6
Chapter
Contents
6A Overview & Specification 6D Quality Management & Maintenance

1 Hardware Configuration.................................. 1 1 Maintenance During Quality Alarms ............. 1
2 Quality Management Overview...................... 2 1-1 Cyclical Unevenness Maintenance
2-1 Yarn Clearer Quality Control Functions Methods
2-2 MSC Clearing 1-2 Maintenance Points When
2-3 Cyclical Unevenness and Draft Fluctuations Occur in HD Values
Unevenness Management Methods 1-3 Maintenance Points When CV% Errors
2-4 HD & CV% Management Methods Occur
2-5 Slub, Thick Yarn Defect 1-4 Maintenance Points When MN1/Y Values
2-6 Class Cut Are Significantly Higher than Machine
2-7 Curve Cut Averages
2-8 MSC-F foreign material/colored yarn 2 Maintenance and Inspection of the Detection
defect detection Part.................................................................... 8
2-1 Cleaning the Detection Part of the
6B Operation Yarn Clearer
2-2 Checking Operation
6C Operation During Lot Changes 3 Troubleshooting............................................... 9
2019.12 Doc No. V086

Chapter
6A Overview & Specification
Sec 1 Hardware Configuration

6A
Chap
Sec
1
Yarn clearer
VOS
● VOS
This system is used to make various settings and monitor operation.
● Yarn clearer
A photoelectric method is employed to convert the unevenness signal from the detection part into an electric
signal. Yarn clearer analyzes the degree of the yarn unevenness (HD, CV%) and measures the cyclical
unevenness. There are two types of yarn clearer below.
MSC Yarn diameter index detection
MSC-F Yarn diameter index detection & foreign material detection
1 Doc No. V086

Chapter 6A Version 190601
Sec 2 Quality Management Overview
2-1 Yarn Clearer Quality Control Functions
2-2 MSC Clearing
2-3 Cyclical Unevenness and Draft Unevenness Management Methods
2-4
2-5
HD & CV% Management Methods
Slub, Thick Yarn Defect
6A
Chap
2-6 Class Cut
2-7 Curve Cut Sec
2
2-8 MSC-F foreign material/colored yarn defect detection
2-1 Yarn Clearer Quality Control Functions

An MSC clearer is mounted for VORTEX spinning allowing for nearly real-time monitoring of yarn quality during
spinning. Due to the wide range quality levels required depending on the market and type of cloth, there needs
to be a flexible approach to yarn quality control. It is essential that the quality control be properly adjusted to
the quality level required by the end use.
● Main quality management standards

• Yarn diameter index is correct and within the criteria.
• The yarn strength and fluctuation of yarn strength stay within the quality level that the final product requires.
• Yarn defects, such as slubs, neps, thick yarn and thin yarn, occur less than what the quality criteria
prescribes.
• Hairiness number and periodic thickness unevenness are within quality standard ranges
Functions supported by yarn clearer

It is important to not only cut off defects and detect the spinning unit which is lowering product quality, but also
to trace the root cause of the yarn defect and correct it. Yarn defects detected by the clearer are as shown in
the following table.
Function Purpose Example of detection target
•Detects small defects such as neps and slubs

•Detects defects, which could possibly cause cloth defects,
Yarn defect such as thick yarn or thin yarn, where compared with slubs Nep, slub, thick yarn, thin yarn
and neps, the fluctuation in thickness is smaller but the length
of the defect is comparatively long.
Foreign material,
Detects foreign material or colored yarn defects. Colored yarn defects
colored yarn defect
Yarn diameter Yarn count irregularities, yarn
Detects yarn with different yarn diameter.
index with excessive hairiness
Super Spectron Detects unevenness of thickness in yarn that occurs cyclically. Top cots defect
Continuously detects the fluctuation in yarn quality that occurs Yarn that continues to have
Hairiness Data
in short time intervals and uses this data to detect faulty small defects not removed
(HD)
spinning units where quality fluctuations occur. through clearing, weak yarn
The system processes a measured length of about 1,000 m
Top cots deterioration,
and then uses the data, which is void of fluctuation caused by
CV% of yarn large fluctuation in yarn
short defects, to detect the fluctuation of data between lots,
diameter index physical properties between
and the deterioration of consumerables over one day, one
lots
week etc.
For short defects, the objective is to remove defects according to fixed criteria, but when there are many
defects that do not get removed and the amount of defects reaches the level where it impacts on the overall
appearance of the yarn (cloth), these defects are detected by other functions.
If defects are occurring cyclically, Super Spectron is used to detect the defects, and identify what is causing the
defects to occur. If the defects are not cyclical in nature, and occur sporadically, Hairiness Data (HD) is used to
detect the defects. HD can be used to detect sporadic fluctuation, but when this fluctuation is occurring on all
spinning units over an extended period (for example, few days or one week), CV% is used to perform quality
control.
2 Doc No. V086

Images of defects
● Slub defects are detected by "N and S".
6A
Chap
Sec
2
● Colored yarn defects are detected by "FFD".
● Thick and thin yarn defects are detected by "L and T".
Thick yarn
Thin yarn
● If there is long lengths of thick or thin yarn and the fluctuations are small, the defects are detected
by "yarn diameter index (Φ)".
● If many slubs occur that are smaller than the “N and S” clearing setting, the defects are detected by
"HD".
If there are a large number of small defects, it will cause cloth defects.
When small slubs occur in large

volumes, it changes the yarn's
appearance.
Normal yarn appearance
3 Doc No. V086

● If defects are smaller than the clearing setting and thick and thin yarn (unevenness) cyclically
occurs, this is detected by "Super Spectron".
Cyclical unevenness
6A
Chap
Sec
2
When this type of defect is taper wound, it produces a distinct moiré pattern.
● When defects occur during spinning and the hairiness increases, these defects are detected by
"HD".
When the hairiness

of yarn increases, the
overall appearance is
whiter.
4 Doc No. V086

● An absolute value called the CV % is used to compare values regarding the identification of
spinning units that have quality irregularities, differences between lots and deterioration of yarn
quality caused by deteriorated consumables.
This method is performed in addition to the detection by the above methods in this section. When this
comparison is made, it is measured over a longer period so that fluctuations caused by small defects can be
kept in check.
6A
Chap
Clearing by
L and LL Sec
2
Generally, as hairiness
increases, the fluctuation
Clearing by in the yarn diameter index
Clearing by
N and S increases and defects can
T and TT
be detected by HD.
Defect smaller
than the clearing
setting
Yarn diameter
Small and thin defects less

Detection by HD Yarn length
index
than the clearing setting
Interpretation of CV% data for

certain time
Threshold value for
CV% quality control
Time
An extremely easy to understand example is deterioration of top cots.

It is assumed that the quality deteriorates over 240 hours and that the quality control threshold is reached.
As the top cot deteriorates, the control of the fibers being guided from the front rollers into the fiber guide
worsens and this causes gradual deterioration of the yarn’s physical properties. When the quality control
threshold is reached, the top cot is replaced.
To describe this process another way: first there are not many defects that do not satisfy the quality control
criteria, but then the defects gradually increase. The increase in defects worsens physical properties of the
yarn. When small yarn defects that cause a deterioration of the yarn’s physical properties rise above a certain
level within a certain length, that portion can cause problems with the cloth quality. The occurrence of such
problems can be detected by “HD”.
Moreover, there are cases where damage occurs due to nozzle choke etc and part of the outer periphery of
the cots is chipped before the physical deterioration of the yarn occurs. When spinning is performed in this
condition, cyclical defects can start to occur and the yarn under these circumstances will be detected by the
Super Spectron.
When the top cots deteriorates to a point that is outside the quality control standard, they can be detected by
“CV %”. Because these quality fluctuations take a long time to occur and are subject to fluctuation gradually,
the HD, which detects based on machine average standards and spinning unit (SP) average standards, cannot
detect them. This is because the standard values shift gradually. The quality control limits of CV% is set by
absolute values and this allows fluctuation that occurs over long periods to be detected.
5 Doc No. V086

2-2 MSC Clearing
With MSC clearing, you can adjust the defect removal settings to the ideal setting through the use of MSC
classification to observe the yarn defects.
* Yarn defect evaluation based on MSC classification will not perfectly match the measurement results of
USTER CLASIMAT. Take this into consideration when specifying the settings.
Setting Description 6A
Chap
N Cut when there is a lump which is <setting>% or more.
S Cut when there is a lump equal to or more than <setting>% for <setting> cm. Sec
2
L Cut when there is a thick yarn equal to or more than <setting>% for <setting> cm.
LL Cut when there is a thick yarn equal to or more than <setting>% for <setting> cm.
T Cut when there is a thin yarn equal to or less than <setting>% for <setting> cm.
TT Cut when there is a thin yarn equal to or less than <setting>% for <setting> cm.
Φ Cuts yarn when yarn diameter index is outside the setting range.
* Separate to the above settings, it is also possible to cut yarn by classifying and specifying the yarn defects
by using MSC classification.
Example of MSC clearing settings

When “+100 %, 2.0 cm” is set for MSC clearing, the yarn will be cut if a defect larger than a hypothetical
rectangular defect of "+100 %, 2.0 cm” is detected.
For the cut to be performed, the surface average of the yarn defect part must exceed setting values (+100 %)
for the specified length (2.0 cm).
+100 %
2.0 cm Size of the hypothetical yarn defect
+100 % +100 %
2.0 cm 2.0 cm
This defect did not result in a cut because This defect did result in a cut because the
the average value across 2.0 cm did not average value across 2.0 cm exceeded
exceed +100%. +100%.
This shows how the MSC clearing evaluation does not always match with yarn appearance.
If the yarn defect does not satisfy the specified length but the size of the part that exceeds the average
(surface area of signal) is larger than the hypothetical model defect, the yarn is cut.
1.0 cm +200 % 0.67 cm +300 % 0.5 cm +400 %
6 Doc No. V086

Differences between MSC clearing and MSC classification
[MSC clearing]
A
6A
Chap
Sec
2
MSC clearing measures the surface area of the part that exceeds the average value as a yarn defect. Because
this method measures the gray portion of the above figure, there is a difference between the defect size
evaluations of A and B.
[MSC classification]
B
A +65 % threshold Size of defect
Defect length
MSC classification evaluates the size of the yarn defect by using the length of the yarn defect and the
maximum value (peak value) of the yarn defect. For example in the case of a slub defect, MSC classification
evaluates the length of the part with a thickness of +65 % of the standard value as the defect length. If there is
a yarn defect such as A or B in the above figure, the shapes may differ but evaluation by MSC classification will
be the same.
MSC clearing: A < B
MSC classification: A = B
Defects are plotted on the defect map based on MSC classifications. In addition, clearing is evaluated using
the surface average of the yarn defect part. As such, points which exceed the clearing curve on the defect
map but are not cut, are because the evaluation methods for each are different and this does not indicate a
problem.
(red): Cut defects

(green): R
emaining
defects
7 Doc No. V086

2-3 Cyclical Unevenness and Draft Unevenness Management Methods
Super Spectron
With VORTEX 870, the yarn clearer (MSC) allows for real-time verification of all yarn quality during spinning.
However, due to picking up yarn unevenness signals within short intervals, a certain degree of fluctuation in
measurement values is unavoidable. The function that performs a frequency analysis of the collected yarn
unevenness signal and detects “cyclical thickness unevenness” of the yarn is called the Super Spectron.
6A
Chap
Sec
2
Effects of cyclical unevenness on fabric quality
The cyclical unevenness of the yarn can cause defects on the surface of final products such as woven or
knitted fabric, which can cause the fabric quality to be downgraded.
The relationship between cyclical unevenness of the yarn and defect patterns appearing on the surface of
woven fabric is not completely clear in all cases; however, the information explained later has been determined
from experience. However the problem here is that the judgment of cyclical unevenness is by visual inspection,
which makes it difficult to establish clear judgment criteria.
The judgment criteria that determine whether or not the cyclical unevenness of yarn has impacted on fabric
quality differ enormously depending on the following conditions.
• The specific requirements of the market where this yarn is destined
• Choosing to use the yarn for knitted fabric or woven fabric
• Types of woven fabric that use the yarn
• Whether the yarn is used for the warp or weft of woven fabric
Strictly speaking the criteria for judging yarn quality must be adjusted to reflect the above conditions. It
is therefore important to set the most reasonable quality control level of the yarn that is in line with these
judgment criteria.
8 Doc No. V086

Relationship between yarn cyclical unevenness and the quality of the woven or knitted fabric
Examples are given below to explain how the cyclical unevenness of yarn can cause defects in woven and
knitted fabrics.
Generally, if the yarn has short cyclical unevenness, defects will arise when the yarn is used as the weft, if the
yarn has long cyclical unevenness, defects will occur when the yarn is used as the warp.
● If the unevenness cycles are short (7 to 10 cm) and the yarn is used for the weft of woven fabric 6A
Chap
Depending on how the cyclical unevenness of the yarn combines with the width of the woven fabric, patterns
described as “moire”, “choppy”, and “wavy” appear on the fabric.
Sec
2
[How a typical moire defect presents itself]
[How a typical choppy defect presents itself]
[How a typical wavy defect presents itself]
By changing the width of the fabric or the tension of the weft yarn it is sometimes possible to make cyclical
unevenness less visible. When yarn with this kind of short cyclical unevenness is used for the warp, it is less
likely to result in a defect on the woven fabric.
9 Doc No. V086

● If the unevenness cycles are long and the yarn is used for the warp of woven fabric
When yarn with long cyclical unevenness is used for the weft, it is unlikely to cause any problems. This is
because the width of the woven fabric is shorter than the cyclical unevenness and defect patterns tend not
to appear when the cycles do not overlap. Note however that if long cyclical unevenness yarn is used for the
warp, the long cycles overlap causing a “streaky” defect.
[Image of streaky pattern caused by warp yarn] 6A

Chap
Sec
2
When 5 to 10 strands of a slightly thinner portion of the warp yarn are lined up together, it causes thin streaks
in the woven fabric.
In a case where 4 to 6 beams take yarn from one package and the package has yarn with a significant cyclical
unevenness, the yarn with the cyclical unevenness will overlap in the same positions of the 4 to 6 beams. If this
occurs, it is sometimes possible to remedy the problem by dispersing the placement of the beams receiving the
yarn from the same package on the creel of the sizing machine.
When the sliver is thin, long streaks are sometimes visible because the thin yarn is directly spun. It is important
to exercise due care when using the MVS where sliver is directly supplied.
● For knitted fabric

When yarn with short cyclical unevenness is used for knitted fabric, it will cause defects on the fabric surface.
If yarn has long cyclical unevenness and many thin portions, streaky defects can occur.
10 Doc No. V086

Causes of cyclical unevenness
The occurrence of a cyclical unevenness called draft waves cannot be avoided in spun yarn because an
aggregate of short fibers is drafted by draft rollers. It can be theoretically explained that the cycle of these
draft waves will be 2 to 3 times the length of the fibers. This cyclical unevenness will increase as the draft ratio
is increased. It will also increase when floating fibers during drafting are not controlled. Examples are given
below.
6A
Chap
● When the draft ratio is unappropriate
The short cyclical unevenness (7 to 10 cm) or the long cyclical unevenness (more than 1 m) increases.
Sec
2
1 2 3 4
Main draft ratio Intermediate Break draft ratio

draft ratio
When the main draft ratio is too When the break draft ratio
large, cyclical unevenness of becomes too large, the cyclical
about 8 cm will increase. unevenness of 8 cm will be
multiplied by the main draft ratio
(for example 40×) to equal cyclical
unevenness of about 3.2 m.
Wave length
1 cm 2 5 10 20 50 1m 2 5 10 20 50 100 200
● When comb noil or poor quality cotton is mixed in

When there is an increased volume of short fibers, it is difficult to control the floating fibers in the drafting part
and cyclical unevenness will increase.
● When the slippage between the fibers is inadequate

If the slippage between fibers is inadequate due to too much sugar in the cotton fibers, not adequate lubricant
in the polyester fibers, or poor dyeing methods etc., it will not be possible to control the floating fibers and
cyclical unevenness will increase.
● When the supply sliver already has cyclical unevenness

Even in cases where cyclical unevenness is not prominent in the sliver, it can still cause cyclical unevenness in
the yarn.
● When there are differences in preprocessing

Cyclical unevenness will typically increase when carded sliver, which is less even than combed sliver, is used.
● Mechanical causes when using VORTEX 870

• When the front top roller (top cot) has surface damage or eccentricity
• When the front bottom roller has surface damage, eccentricity, or foreign material stuck to it
• When the apron rollers have significant eccentricity
• When there is damage to the apron (scratching or age-related)
• When foreign material is stuck or there is wrap up on any roller
11 Doc No. V086

Frequency analysis of yarn unevenness
The USTER spectrogram shows by graph the degree of cyclical unevenness of the yarn in a way that is easy to
compare regardless of yarn count.
[USTER spectrogram]
6A
Chap
hp
ho Sec
2
1 cm 2 5 10 20 50 1m 2 5 10 20 50 100 200 500 1 km 2 5
On the other hand, the spectral frequency analysis results of the Super Spectron show the absolute values as
numerals. Because of this, when the yarn becomes thicker, the fluctuation is greater, which results in larger
values.
Short cyclical unevenness

(Mainly detects front top
cots and front bottom roller
cyclical unevenness)
Long cyclical unevenness

(Mainly detects 3rd
and 4th roller and other
comparatively long cyclical
unevenness)
12 Doc No. V086

Example of Super Spectron settings
The quality required for yarn differs by spinning factory, and the quality management level also differs
depending on product applications. Setting examples are shown below.
● Setting the initial values for alarm levels and stop levels
1. Carry out spinning on all spinning units within possible limits and collect short cycle data.
2. Check the machine average values for the Top and Bottom and confirm the dispersion (standard 6A
Chap
deviation (σ)).
Displayed on VOS screen.
3. Set “machine average value +3σ" for the alarm levels for Top and Bottom. Sec
2
* If the σ of any item exceeds 30, it is important to use USTER TESTER to measure the yarn being
produced by the spinning unit with the high value and recheck whether the peak (protruding part of bar
graph) is at a problem-causing level.
[How to view the USTER spectrogram]
hp
ho
1 cm 2 5 10 20 50 1m 2 5 10 20 50 100 200 500 1 km 2 5
If the degree of unevenness (hp) sticking out at a certain frequency in the USTER spectrogram exceeds
50 % of the degree of unevenness before and after on the graph (ho), there will be a visible defect on the
fabric surface. The USTER TESTER has a feature that highlights serious errors on the spectrogram to make
identification easier.
● Revising settings for the alarm levels and stop levels

The above settings are only a guide, and it is recommended that appropriate alarm level and stop level settings
be configured using the Super Spectron and USTER spectrogram after examining required quality levels.
[Example] When you wish to have strict quality control Machine average value +2σ
When you wish to have loose quality control Machine average value +4σ
Measure the yarn for which the alarm occurred, and inspect to decide when to loosen or tighten.
* Even when cyclical unevenness occurs, it is important to consider whether it is just the data of the Super
Spectron and the USTER spectrogram that is affecting the quality or whether the quality is also affected by
the CV% and HD data from MSC clearing and the CV% and IPI data from the USTER TESTER.
13 Doc No. V086

2-4 HD & CV% Management Methods
Yarn error detection by HD

By detecting deviations and changes in the yarn diameter, HD can identify bad spinning units and determine
the state of the yarn on each spinning unit. Experience has shown that detection of the following errors in yarn
is possible.
● Errors in the drafting part
6A
Chap
• Deposition of foreign material on bottom roller
• Build up of fiber waste on bottom collector Sec
2
• Defective top cots
• Apron belt damage
• The trumpet guide, condenser and fiber guide are not aligned in a straight line
• Cots and yarn path centers are misaligned (Cot press defect, etc.)
• Apron tensioner error (Bad rotation, vibration etc. resulting from use of defective apron)
● Errors in the spinning part
• Spinning part (spindle, fiber guide, etc.) damage, deposition of foreign material
• Sudden nozzle hole blockage
• Spinning position switching plate setting mistakes
● Other
• Sliver causes
• Wrapping up, weak yarn
• Dirty yarn clearer head
• Continual occurrence of small slubs and neps not requiring defect removal
Settings for MSC clearing by HD value

Set standards according to the required quality standards.
● Setting the HD and HD Ave. upper/lower limit values

[List of reference HD value settings for every end-use]
Blended or 100 % cotton 100 % synthetic
HD not
Carded cotton Combed cotton Spinning status
required
Woven Knitted Woven Knitted Unstable *1 Stable *2
HD upper limit (formula) Normal Strict Normal Strict Normal Strict Loose
HD lower limit (formula) Loose Normal Normal Strict Normal Strict Loose
HD Ave. upper limit
Loose Normal Normal Strict Normal Strict Loose
(value)
HD Ave. lower limit
Loose Loose Normal Normal Loose Normal Loose
(formula)
* Select one of 3 levels, “Strict”, “Normal” or “Loose” or directly input a value (%) on the VOS screen.
* For the HD machine average and σ, refer to the HD monitor value and σ monitor value displayed on the VOS
screen.
less than 0.8 Stable
HD σ
1.00 or more Unstable
If σ is 1 or more, there may be a spinning unit which is spinning yarn of unstable quality. Refer to Chapter 6D
and check the spinning unit.
14 Doc No. V086

[HD]
By using judgments based on deviation from the machine average, it is possible to identify yarn quality errors.
Use the above table for the initial settings and then gradually loosen the setting if spinning yarn for knitted
fabric or gradually make the setting stricter if spinning yarn for woven fabric.
[HD Ave.]
By setting the deviation based on the standard value for each spinning unit, you can identify fluctuations in 6A
quality on every spinning unit. As well as HD, use the values in the above table for the initial settings and Chap
gradually loosen for knitted fabric and gradually make stricter for woven fabric.
Sec
2
● Exceptions
When there is a large difference in the standard deviation (σ) of the HD value between spinning units or when it
is difficult to decide on a setting, refer to the following for setting the HD upper and lower limit values.
1. Measure the hairiness data in order beginning from the spinning unit with the highest HD value.
2. Compare the data with that of a normal spinning unit (spinning unit with a low HD value).
3. Decide on the upper limit of the HD value from these results. If there is also evenness data, refer
to this as well.
Skip function for small neps and slubs

When the HD calculation is performed on yarn diameter index data as it is, the calculation is affected by slubs
and neps that did not satisfy the MSC clearing settings and the HD values will change suddenly. Depending on
the product, it is not necessary that the changes of this type be identified as defects which need to be cut. If
this is the case, there is a function to skip these defects. Set the settings appropriate to suit the end-use of the
yarn.
[List of skip settings for small slubs and neps for every end-use]
Woven Knitted Woven Knitted
Raw material Carded cotton Combed cotton
HD filter level 50 % (Loose) 100 % (Normal) 100 % (Normal) 150 % (Strict)
* When “100 %” is set for “HD filter level”, signals more than 100 % of yarn diameter index (200 % of original
yarn) will be calculated as 100 %. Therefore as the value (%) in this case is smaller, it becomes harder
for the effect of small neps and slubs to be picked up and the looser the setting will be in respect to yarn
diameter index fluctuation.
* Do not set a value less than 50 %.
For example if the HD filter level were set to 50 %, it will

not be possible to detect these small neps and slubs that
occur repetitively.
15 Doc No. V086

[HD Ext after splice]
There is a function for comparing standard values before and after yarn threading and for cutting if there are
any large changes. However, because the changes in yarn unevenness immediately after yarn threading etc.
by the AD are large, normal settings are too strict and yarn threading may not be possible. So after splicing,
until a new standard value is determined, the pre-splicing value can be loosely set. The value should be ±%
extended value of the standard value before splicing.
6A
[No. of HD AVE previous threshold value resets] Chap
This is a function which allows for the pre-splicing standard value to be reset after repeating a set number of
cuts if the pre-splicing standard value is determined to have been an error and cutting is carried out. Sec
2
If the post-splicing HD fluctuation is large, cutting may be repeatedly carried out, so settings should be
configured to avoid this. Set the number of cuts to count before resetting.
Evenness CV%
The yarn quality that changes due to the yarn's short-term fluctuation and bad spinning units can be controlled
using HD, and the cyclical unevenness of yarn can be controlled using the Super Spectron. However, if quality
deteriorates gradually over a long period of time, detection may not be possible.
Yarn quality control by evenness CV% is aimed primarily at detection of fluctuation of longterm yarn quality
fluctuation (deterioration of consumables, variation in raw materials, and differences between lots).
The following types of yarn quality changes can be detected.
• Long-term variation of raw materials
• Variation from changing lots
• Changes to yarn quality due to incorrect machine settings
• Changes to yarn quality due to deterioration of consumables such as top cot and apron
• Changes to yarn quality caused by bad sliver or bad spinning units
16 Doc No. V086

2-5 Slub, Thick Yarn Defect
Slub clearing settings

Configure settings according to Chapter 5B, Screen ID <11430>.
If a large number of yarn breaks occur, review the materials, spinning conditions and clearing settings, and if
any remaining defects occur, analyze a sample of the remaining defects then configure appropriate clearing
settings.
6A
Chap
Check the current clearing curve position, cut and remaining defects on the VOS screen. Based on this
distribution chart, set a clearing curve position which allows for a realization of an appropriate clearing curve Sec
2
without excessively increasing the yarn breaks.
Thickness defect clearing settings

● Settings for L, T
The following settings control the detection of thick yarn and thin yarn caused by irregular drafting and
occurrences of wrap up.
[Setting guide]
Length
Setting % When to use
(cm)
This setting is only appropriate if there is a high percentage of synthetic
15 20
fiber and the original yarn is very stable.
This setting is appropriate for knit-grade yarn when yarn must be high
20 20
L quality.
25 20 General purpose setting.
This setting is appropriate for weaving-grade yarn when thick and thin
30 30
portions are not problematic.
This setting is only appropriate if there is a high percentage of synthetic
15 20
fiber and the original yarn is very stable.
This setting is appropriate for knit-grade yarn when yarn must be high
20 20
T quality.
This setting is appropriate for weaving-grade yarn when thick and thin
30 30
portions are not problematic.
* Fix the length to 20 to 30 cm and set as strictly as possible without hindering operation.
* For knit yarns with strict quality standards set to approximately 20 %.
● Settings for LL, TT

The following settings control the detection of thick yarn and thin yarn caused by thick and thin portions
contained mainly in the sliver.
[Setting guide]
Length
Setting % When to use
(cm)
This setting is only appropriate if there is a high percentage of synthetic fiber
10 100
and the original yarn is very stable.
LL
12-15 100 This setting is appropriate for knit-grade yarn when yarn must be high quality.
This setting is only appropriate if there is a high percentage of synthetic fiber
10 100
and the original yarn is very stable.
TT
12-15 100 This setting is appropriate for knit-grade yarn when yarn must be high quality.
17 Doc No. V086

2-6 Class Cut
The yarn defect removal by the clearer can be set to the slub and Nep detection method, then on the MSC in
addition to clearing the classified defects can be specified based on MSC classification and cut (class cut).
* Refer to Chapter 6A, 2-2 for differences between MSC clearing and classification.
To cut specific remaining defects, adjust the appropriate yarn defect removal settings. 6A
For the clearing curve method, settings will become more strict the more the curve is lowered, leading to Chap
cutting of other zones as well. As a result, the number of cuts may increase, lowering production efficiency.
Using the class cut method instead allows only the desired cut zone to be set. Sec
2
[Ex.] Removing remaining defects in the C1 zone on the clearing curve

● If the clearing curve is corrected
The red line in the image below indicates the clearing curve when S; 75 % 2.0 cm.
The settings for other zones (B1 etc.) will also become more strict, so the number of cuts will increase.
● If the zone is specified

The B1 etc. clearing settings will remain the same and only the C1 zone settings can be added.
18 Doc No. V086

● Defect removal setting
The setting for defect removal should result in the least possible yarn cut but with all remaining defects within
the allowable range, while maintaining watch over remaining defects. Refer to Chapter 5B for settings.
Class cut 6A
Chap
Sec
2
Clearing curve
* In some cases uncut defects may still occur even if the clearing curve on the defect map is exceeded. This
is because of detection method differences as shown in Chapter 6A, 2-2. If these type of remaining defects
will become problems with the yarn quality, use the above-noted class cut method to manage them.
Uncut defects even if the

clearing curve on the defect
map is exceeded
(red): Cut defects

(green): R
emaining
defects
2-7 Curve Cut

In MSC clearing, yarn defect area is evaluated (Refer to Chapter 6A, 2-2); however, there is also a curve
cutting function for cutting yarn defects based on the plot information saved in the VOS . Clearing simulation is
evaluation based on plotting (based on curve cut).
19 Doc No. V086

2-8 MSC-F foreign material/colored yarn defect detection
In MSC-F foreign material/colored yarn defect detection, it is possible to use FFD classification to observe
foreign material/colored yarn status while configuring appropriate foreign material/colored yarn defect
elimination settings.
* The evaluation based on foreign material classification will not perfectly match the measurement results of
USTER CLASIMAT. Take this into consideration when specifying the settings. 6A
Chap
Setting item Description
Cut when there is a dark and short foreign material/colored yarn equal to or
DS Sec
2
greater than the <setting>% + mm
Cut when there is a slightly darker and long foreign material/colored yarn equal
DL
to or greater than the <setting>% + mm
Cut when there are 2 continuous dark foreign material/colored yarns equal to or
DDS
greater than the <setting>% + mm.
Skips cutting when the foreign material/colored yarn detected in the above 3
Pepper trash skip
channels is determined to be pepper trash
* DDS setting length uses the DS setting (mm).
20 Doc No. V086

FFD foreign material/colored yarn detection settings example
When “- 25 %, 10 mm” is set for DS channel, the yarn will be cut if a defect larger than a hypothetical
rectangular defect of "- 25 %, 10 mm” is detected.
10 mm
6A
Chap
Sec
2
- 25 %
10 mm 10 mm
- 25 % - 25 %
This defect did not result in a cut This defect did result in a cut because
because the average value across 10 the average value across 10 mm
mm did not exceed - 25%. exceeded -25 %.
* The setting darkness (%) definition for foreign material detection is as follows. A completely black section of
the same thickness is defined as -100%.
- 100 %
21 Doc No. V086

FFD foreign material/colored yarn detection and FFD classification differences
[FFD foreign material/colored yarn detection]
A
6A
Chap
Sec
2
The area of sections which exceed average values are measure as defects.
Because this method measures the gray portion of the above figure, there is a difference between the defect
size evaluations of A and B.
[FFD classification]
Foreign material length
- 8 % threshold Foreign
A material
darkness
B
FFD classification evaluates the size of the yarn defect using the length of the foreign material in the yarn and
the maximum value (peak value) of the foreign material. For example, foreign material classification evaluates
the length of a section corresponding to a darkness equivalent to the standard value -8%. If there is foreign
material as shown by A or B in the above figure, the shape may differ but the evaluation by the foreign material
classification will be the same.
Foreign material detection channel: A<B
Foreign material classification: A = B
22 Doc No. V086

DDS channel detection
The DDS channel is a channel for detecting foreign material/colored yarn which has broken into 2 pieces such
as foreign material/colored yarn for which the middle section does not appear on the yarn surface.
• In order to detect upstream or downstream foreign material/colored yarn individually with the DS channel,
the DS channel settings must be made stricter.
• The upstream and downstream are evaluated together in the DDS channel.
• The DDS channel setting (%) can be set slightly stricter than the DS channel setting (%). 6A
Chap
Detection range Data interval Sec

2
Downstream Upstream
Pepper trash skip

The pepper trash skip is a channel in which cutting is skipped in the DS channel, DL channel, and DDS
channel in the following circumstances. Evaluation is carried out based on foreign material/colored yarn and
pepper trash darkness (%) and length (mm).
• If foreign material/colored yarn is detected
• If detected foreign material/colored yarn is determined to be pepper trash
Foreign material/colored yarn
Pepper trash
23 Doc No. V086

Chapter
6B Operation
Clearing is set in VOS. Refer to Chapter 5B MSC Settings (Screen ID <11410~11500>) for operation methods.
1
Chapter
6C Operation During Lot Changes 6B
Chap
Sec
The configured clearing settings will be saved as lot files in VOS and stored in memory. 1
Refer to Chapter 5C for lot file loading methods.
6C
Chap
Sec
1 Doc No. V086

Chapter 6B, 6C Version 190601
Chapter
6D Quality Management & Maintenance
Sec 1 Maintenance During Quality Alarms

1-1 Cyclical Unevenness Maintenance Methods
1-2 Maintenance Points When Fluctuations Occur in HD Values
1-3 Maintenance Points When CV% Errors Occur
1-4 Maintenance Points When MN1/Y Values Are Significantly Higher than Machine Averages
1-1 Cyclical Unevenness Maintenance Methods

If cyclical unevenness occurs carry out maintenance in accordance with the following procedure.
Cyclical unevenness cause characteristics

The main causes of cyclical unevenness can generally be divided into 2 points.
The measures for dealing with them are completely different depending on the causes.
• Cyclical unevenness resulting from poor fiber draft
• Cyclical unevenness resulting from mechanical defects
These will be characteristic unevenness on the USTER TESTER and MSC spectrograph.
6D
● Draft unevenness example Chap
As shown in the below spectrogram, the characteristics of draft unevenness include having a certain degree of
width and mound-like shapes. Sec
1
When the main draft ratio is too When the break draft ratio
large, cyclical unevenness of becomes too large, the
about 8 cm will increase. cyclical unevenness of 8 cm
will be multiplied by the main
draft ratio (for example 40×)
to equal cyclical unevenness
of about 3.2 m.
Wave length
1 cm 2 5 10 20 50 1m 2 5 10 20 50 100 200
● Mechanical defect examples

As shown in the spectrogram below, the characteristic of mechanical unevenness is sticking up in a single
location.
hp
ho
1 cm 2 5 10 20 50 1m 2 5 10 20 50 100 200 500 1km 2 5
* MSC cyclical unevenness measurement is intended to strictly monitor mechanical defects in particular, so
projecting peaks occur in more specific frequency zones as in the spectrogram below.
1 Doc No. V086

Chapter 6D Version 190601
Cyclical unevenness cause correction
● If there is cyclical unevenness in the supply sliver
Check the diagram/spectrogram for finisher slivers.
* Even if there are no peaks on the spectrogram for finisher slivers, cyclical unevenness may occur because
of the drawing frame. For example, unevenness resulting from drawing frame front bottom roller rib pitch is
small at only 2 mm cycle and cannot be seen. If 2 mm is multiplied by TDR time, it can then be seen on the
yarn spectrogram.
● If a draft error occurs in the spinning part

If control of floating fibers is difficult, there will be increased cyclical unevenness. This cyclical unevenness
often appears in the area of 2 to 2.5 times the fiber length.
Draft unevenness
Material Cyclical unevenness length
occurrence locations
100% Cotton 5-6 cm

Between front and
Synthetic 100% (1.5") 7.5-8 cm
middle roller
5-8 cm
Cotton/Synthetic blend
(Tendency to lean towards higher blend ratio)
100% Cotton 5-6 cm × MDR

Between middle roller and
3rd roller Synthetic 100% (1.5") 7.5-8 cm × MDR 6D
Chap
5-8 cm × MDR
Sec
1
100% Cotton 5-6 cm × MDR×IDR
Between 3rd roller and
4th roller Synthetic 100% (1.5") 7.5-8 cm × MDR×IDR
5-8 cm × MDR×IDR
● For Mechanical Problems

Specify the frequency zone on VOS and maintain locations which correspond to each.
VOS display Issue Potential causes
• Cots eccentricity and damage
TOP Peak occurs in "TOP"
• Front top arbor bearing abnormality
• Front bottom roller surface abnormality
(Honeydew deposition, fiber wrapping)
BOT Peak occurs in "BOT" • Front bottom roller abnormality
(Surface damage, eccentricity)
• Front bottom roller bearing abnormality
• When drafting synthetic yarn fibers the number of roller gear
ANO Peak occurs in “ANO” teeth in the break draft part is unsuitable
• 3rd roller/ 4th roller drive part abnormality (motor, belt)
* For unevenness in the area of 46-48 mm in ANO display the top cots may be the cause.
2 Doc No. V086

1-2 Maintenance Points When Fluctuations Occur in HD Values
Given below explains various possibilities where sudden fluctuation of HD value can occur due to bad spinning
units and what corrective action should be taken.
● Deposition of honeydew on front bottom roller

Use lever A to release the nozzle assembly and use
the nozzle brush to check that no honeydew have stuck
to the surface of the front bottom roller.
Lever A
● Buildup of fiber waste on the lower part of the

tensor bar 6D
Check that fiber waste hasn't built up on the bottom Chap
part of the apron. If there is a buildup of fiber waste in
this area, use the nozzle brush to carefully remove it. Sec
1
1) Top cots yarn path 2) O

uter periphery and
● Bad top cots end face of cots
Check the following items by looking or touching by
hand.
1) Damage near the top cots yarn path
Check that there is no damage (grooves), surface
roughness or burning in this part.
2) Vibration of outer periphery and end face of cots
Is the end face significantly warped due to poor
press fitting
3 Doc No. V086

● Bad apron
Raise the draft cradle and check by touching with
hands that there is no surface damage on either the
top or bottom apron.
Be careful not to get caught in the

rotating rollers.
● Blockage -of the top suction

If there is a blockage in the top suction path there can
be a buildup of fiber waste in the drafting part and this
can get stuck to the yarn. Check if there is a negative 6D
pressure at the tip of the top suction. Chap
Sec
1
● Sliver damage The damaged

The sliver at the bottom of the can and the small sliver is
amount of sliver that gets handled by operators are conspicuous
vulnerable to being damaged. This damaged sliver by this kind of
can cause deterioration of the yarn properties, so the hairiness.
damaged part must be removed.
Sliver at the
bottom of the can
4 Doc No. V086

● Fiber waste builds up between the tip part of the
top suction and the top cots
When a severe nozzle choke caused by impurities in
the sliver occurs, fiber waste can build up like this.
● Blockage in the suction path beneath the front

roller
Check if the suction entrance is blocked or whether the
pathway is blocked.
6D
Chap
Sec
● For spinning nozzle problems 1
Check that there are no problems or incorrect

attachments.
[Problems]
1) O ring damage and bad attachment
2) Spinning nozzle hole clogging
3) Filter clogging
4) Damage near fiber guide inlet
5) Fiber guide needle section abnormality
6) Spindle forward end loss
Spinning position
switching plate 1) O
ring
5) Spindle
4) Fiber guide
3) Filter
2) Spinning nozzle
[Attachment mistake]
• Spinning position switching plate
• Fiber guide type
• Nozzle type
• Diameter of spindle
5 Doc No. V086

● Clearer head detection part is dirty
• For heads with FFD, check the part that glows yellow
to ensure that both slit side surfaces are not dirty.
• For heads without FFD, check the area in a range of
7 mm from the bottom surface to ensure that both
slit side surfaces are not dirty.
If dirty, clean. Refer to Chapter 2D, 4-3 for cleaning

methods.
1-3 Maintenance Points When CV% Errors Occur

6D
The target changes depending on the CV% setting method. Chap
Sec
1
If configured as "Deviation Settings"
Because mainly the distance between the spinning units is detected, cases where errors are detected in units
of spinning units are common.
The following are given as causes of errors in units of spinning unit.
• Deterioration of consumables (Top cots, apron, 3rd and 4th roller drive timing belt)
• Incorrect settings in units of spinning unit (Condenser size, spindle diameter, spinning position switching
plate)
• Bad sliver
If configured as "Absolute Value Settings"

Cases where quality changes in mainly all machines are increasing, although this is affected by the differences
between spinning units.
The following are given as causes of quality degradation.
● Causes when there are changes in quality compared to previous lots

• Material changes
• Temperature changes
• Lot change setting differences (Setting changes or setting mistakes)
● Causes when changes in quality are detected over a long period of time
• Consumable deterioration (Top cots, apron)
• Material lot changes
• Temperature changes
6 Doc No. V086

1-4 Maintenance Points When MN1/Y Values Are Significantly Higher than Machine Averages
When the MN1/ Y (A1 defects) are significantly higher than the machine average for several consecutive hours,
the unit can be force stopped with an n1 alarm. The following are possible causes.
* Refer to Chapter 5 for unit operation setting methods when an n1 alarm n1 alarm occurs.
Black line: Machine average

Blue line: Selected unit
Yellow line: Alarm threshold
* Only displayed when the time axis
is set to “Hour”.
6D
Chap
Sec
1
● Errors in the drafting part

• Defective top cots
• Apron belt damage
• The trumpet guide, condenser and fiber guide are not
aligned in a straight line
• Cots and yarn path centers are misaligned
(Cot press defect, etc.)
● Errors in the spinning part

• Spinning part (spindle, fiber guide, etc.) damage,
deposition of foreign material
● Other
• Sliver causes
• Dirty yarn clearer head
• Continual occurrence of small slubs and neps not requiring defect removal
Always stop the machine before replacing the bottom apron belt.
7 Doc No. V086

Sec 2 Maintenance and Inspection of the Detection
Part
2-1 Cleaning the Detection Part of the Yarn Clearer
2-1 Cleaning the Detection Part of the Yarn Clearer
Item Frequency Notes
Cleaning of the detection part (slit) using the

cleaning tool kit Adjust the frequency of maintenance to
Once/month
reflect the rate at which dirtiness occurs.
Clean the yarn guide and inspect for cracks
* If cleaning with water is difficult, use the following substances.

MSC Alcohol
MSC-F Lighter fluid (such as Zippo oil)
6D
Chap
Use only the specialized cleaning tools for cleaning of the detection part. Do not use any
other materials or metal tools (such as a nozzle brush). Using other materials or tools could Sec
2
damage the detection part. For details, refer to Chapter 2D, 4-3.

● Inspecting the cables
Check that the cable of the yarn clearer detection part is attached in the correct position.
If the cable hangs down, it could become disconnected due to the travel of the carriage.
● Trial operation
Turn on the main switch on the main control box and wait several minutes. If the LED of the yarn clearer
detection part turns on green, you can start the trial operation. (When starting yarn production, run the
machine in warm up operation for about 15 minutes after turning the power on.)
● Check the following after setting the appropriate sensitivity.

• When the yarn is traveling, the spinning unit should be able to perform continuous spinning.
• When the yarn is removed from the yarn clearer head while the yarn is traveling, the “Yarn break alarm”
should occur.
8 Doc No. V086

Sec 3 Troubleshooting
When alarms appear on the VOS screen, take the remedial action detailed for these alarms. See below for
details on other types of trouble.
Status
Phenomenon Cause Remedy
Display
Clean the detection part (slit part).

* After cleaning, the LED (green) can take several
The yarn clearer LED
minutes before it turns on.
(green) does not turn on You cannot perform zero
, for a particular spinning calibration. Check the connector at the rear is properly
unit. connected.
Replace the sensor
Press the reset switch of the MSC(-F) board.
The yarn clearer LED Check the power connector for the MSC(-F) board
(green) does not turn on The MSC(-F) board is is properly connected.
for four spinning units in not functioning normally.
a row.
Replace the MSC(-F) board.
* If it is replaced with a spare board, remember to
6D
Chap
set the address switch (See electric drawings)
and download the program.
Sec
3
The yarn clearer LED
The MSC(-F) boards are
(green) of all spinning Check the yarn clearer power voltage (± 15 V).
not functioning normally.
units does not turn on.
Spinning cannot Check the yarn clear settings are appropriate.

be performed on a
No display --- Check the ø setting values are appropriate.
particular spinning unit or
all spinning units. Set the yarn count setting on the VOS screen.
The evaluation board 7
Memory backup error Press the reset switch of the MSC(-F) board.
segment LED E2 display
CAN communication
The evaluation board 7 (communication with unit
Check the CAN communication connector.
segment LED E3 display control board MS-SPC)
error
CAN communication
The evaluation board 7 (communication with unit
Check the CAN communication connector.
segment LED E4 display control board MS-SPC)
error
RS485 communication
(communication with Check the RS485 connector.
segment LED E5 display
VOS, CM) error
Clean the detection part (slit part).

* After cleaning, the green lamp can take several
minutes before it turns on.
Yarn clearer head error
segment LED E7 display Check the connector at the rear is properly
connected.
Replace the sensor.
The evaluation board 7 Program not downloaded

Download program from the VOS.
segment LED d1 display on the MSC(-F) board.
* Refer to Chapter 2D, 6-3 for the MSC(-F) board position.
9 Doc No. V086


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VORTEX 870 EX

Yarn Quality Control

6A Overview & Specification 6D Quality Management & Maintenance

2019.12 Doc No. V086

Sec 1 Hardware Configuration

1 Doc No. V086

2-1 Yarn Clearer Quality Control Functions

● Main quality management standards

Functions supported by yarn clearer

Function Purpose Example of detection target

•Detects small defects such as neps and slubs

2 Doc No. V086

● Colored yarn defects are detected by "FFD".

When small slubs occur in large

Normal yarn appearance

3 Doc No. V086

When the hairiness

Normal yarn appearance

4 Doc No. V086

Small and thin defects less

than the clearing setting

Interpretation of CV% data for

An extremely easy to understand example is deterioration of top cots.

5 Doc No. V086

Example of MSC clearing settings

2.0 cm Size of the hypothetical yarn defect

1.0 cm +200 % 0.67 cm +300 % 0.5 cm +400 %

6 Doc No. V086

(red): Cut defects

7 Doc No. V086

8 Doc No. V086

[How a typical moire defect presents itself]

[How a typical choppy defect presents itself]

[How a typical wavy defect presents itself]

9 Doc No. V086

[Image of streaky pattern caused by warp yarn] 6A

● For knitted fabric

10 Doc No. V086

Main draft ratio Intermediate Break draft ratio

● When comb noil or poor quality cotton is mixed in

● When the slippage between the fibers is inadequate

● When the supply sliver already has cyclical unevenness

● When there are differences in preprocessing

● Mechanical causes when using VORTEX 870

11 Doc No. V086

1 cm 2 5 10 20 50 1m 2 5 10 20 50 100 200 500 1 km 2 5

Short cyclical unevenness

Long cyclical unevenness

12 Doc No. V086

1 cm 2 5 10 20 50 1m 2 5 10 20 50 100 200 500 1 km 2 5

● Revising settings for the alarm levels and stop levels

13 Doc No. V086

Yarn error detection by HD

Settings for MSC clearing by HD value

● Setting the HD and HD Ave. upper/lower limit values

14 Doc No. V086

Skip function for small neps and slubs

HD filter level 50 % (Loose) 100 % (Normal) 100 % (Normal) 150 % (Strict)

For example if the HD filter level were set to 50 %, it will

15 Doc No. V086

16 Doc No. V086

Slub clearing settings

Thickness defect clearing settings

•Detects small defects such as neps and slubs

1) Top cots yarn path 2) O