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USTER TENSOJET 4 Product Detail |
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ESSENTIAL TEST FOR WEAVING YARNS |
Production speeds in the weaving mill have increased significantly in recent years, as machine technology has progressed. The result is that weft and warp yarns are subjected to higher peak loads than ever – and this becomes a critical factor when it leads to more thread breakages and consequently a potentially disastrous slump in production efficiency. To counter this problem, it is absolutely essential for spinners today to test weaving yarns properly. Serious weaknesses in yarn can be caused by a number of factors: extremely thin places; thick places with little twist; and also yarn contamination by vegetable matter, fly and foreign fibers. Such faults need to be identified, to pinpoint spinning problems and to be able to assess the USTER® WEAVABILITY of a yarn and the number of thread breakages that can be expected. Since many of these weak spots may occur only rarely and at isolated points in the yarn, there is only one way to make sure they are detected – by carrying out a large number of random tests within a short time, using realistic loads. The USTER® TENSOJET 4 is a high-performance tensile strength tester which does exactly that. The advantage is yours – and your customers’.
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CAPACITY MEANS QUALITY |
The testing capacity of the USTER® TENSOJET 4 is immense: as much as 24 running kilometers of yarn per hour. This level of power and speed means that periodic and near-periodic breaking-elongation failure can be detected for the first time. These faults are costly in subsequent processing, which is why the USTER® TENSOJET 4 goes a step further, by providing a display of periodic faults in a spectrogram – a great help in detecting possible errors and preventing them. And the system’s massive test capacity – up to 30,000 breaks per hour – allows yarn faults or isolated weak places that occur only infrequently to be detected and steps to be taken to fix the problem. For the spinner, this gives your yarn trading a firm foundation and paves the way to higher profitability. |
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USTER® TENSOJ ET 4 – OPERATING PRINCIPLES |
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Conventional strength testing merely analyzes the physical strength and elongation of a yarn sample, to arrive at an average value for its strength. This, however, cannot give a true indication of a yarn’s likely behavior during further processing. To do this, we need to increase both the number of samples taken and the speed of processing. The testing operation comprises four stages. First, moving rollers draw the yarn continuously from the package at a preset speed. The yarn is then sucked into a storage zone. Next, the yarn is then passed, via two pairs of rollers, into the measuring zone, where a system of moving clamping rollers effect a strain on the yarn until it breaks. Finally, lint is automatically sucked out of the system. These process stages are synchronized and simultaneous operation of individual functions maximizes throughput rates. |
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ISOLATED WEAK PLACES –
WHAT STATISTICS CANNOT REVEAL |
A series of in-depth evaluations, each based on analyses of 100,000 yarn breaks, have shown that the real weak places – defined using USTER® TENSOJET 4 – are actually to be found at deeper levels of break and elongation measurement than was previously assumed. In short, the dangerous weak places just cannot be detected using traditional testing or conventional statistical methods!
Your customers will rightly complain when rare weak places trigger problems under load peaks during further processing. These problems cause massive decreases in production efficiency. They amount to major economic losses just waiting to happen!
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PREVENTING COSTLY PRODUCTION SETBACKS |
How a yarn will behave during demanding subsequent processes such as weaving can only be reliably predicted by correct classification of measurable yarn characteristics – such as tensile strength and the incidence of isolated weak places – balanced against actual thread loads in the process.
The USTER® TENSOJET 4 enables detailed yarn profiles to be established, taking account of both the yarn quality demanded for the endproduct and the accurate prediction of yarn behavior that the system makes possible.
Unplanned downtime lowers both economic efficiency and weaving quality, while also damaging profit margins not only for the weaver, but also for the yarn producer, who has the added worry of dealing with some expensive complaints from his customer. |
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USTER® WEAVABILITY – A STEP CLOSER TO REALITY |
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The graph here shows that the weft yarn (left) broke 15 times on the weaving machine, with a weak place level of 35.5 cN after 100,000 insertions. So in this example a 10% lower level of genuine isolated weak places means a 60% higher rate of breakage of the weft yarn. The production setbacks resulting from this level of breakage can turn a profit into a loss for the weaving mill.
The alternative? Optimize your purchasing strategy with the USTER® TENSOJET 4 and save on extra expense by making an accurate, targeted forecast of how your purchased yarns will behave on the weaving machine. Measuring across 100,000 breaks with the USTER® TENSOJET 4 – that’s what USTER® WEAVABILITY means... |
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PERCENTILE VALUES INDICATE WEAK PLACE LEVEL |
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The USTER® TENSOJET 4 uses percentile values to indicate the level of the weakest parts of a yarn. If there are isolated weak places, they reveal themselves as “outliers” – extreme deviations from the scatter plot. The percentile value indicates the exact level of these weak places. In a modern spinning mill, the interaction between the fiber material, the spinning process and the yarn count plays an overriding, central role. Even the smallest fluctuations in the fiber material or in the spinning process can cause an increase in the number of isolated weak places. This can often be traced back to the spinning limit of the cotton fibers used.
Faults such as these can be detected only by physical tensile tests with the widest scope. If these faults only become visible in further processing – as is the case with Yarn 1 in the accompanying graphic (12.5 stops) -- then considerable financial losses may be expected.
In this example, an USTER® TENSOJET 4 would have given very rapid payback.
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PLATFORM FOR PROFITABILITY |
With its high-capacity testing and its user-friendly analysis tools, the USTER® TENSOJET 4 is the only realistic method of forecasting the true USTER® WEAVABILITY of a yarn. It is based on state-of-the-art technology, making it easy to use, with minimal operator attention. Backed by the unrivalled testing expertise of Uster Technologies, the relevance and quality of its measurements is assured. Compatibility with the recognized international benchmarking of USTER® STATISTICS for elongation testing means that users of the USTER® TENSOJET 4 are guaranteed objective and meaningful results, which are accepted throughout the global textile chain. For spinners and their customers, the USTER® TENSOJET 4 provides an ideal platform for mutual satisfaction and optimum profitability. |
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