Yarn Breakage Research Articles

Real-Time Prediction of the Yarn Break Position Using Vibration Measurement.

Warping is a crucial process that connects two main stages of production: yarn manufacturing and fabric creation. Two interrelated parameters affect the efficiency of this technological process: warping speed and the ability to swiftly detect the yarn breaks caused by various defects. The faster a break is detected and the warping machine stopped, the higher the machine's working speed can be. Since the beginning of such devices, various types of yarn break detectors have been proposed, primarily based on different mechanical solutions. To enhance the break detection process, a solution involving the use of an accelerometer to measure yarn vibrations and thereby detect whether the moving yarn has broken is proposed. Based on the detection of a threshold value of 22 m/s2, the warping machine could be stopped within 2.752 to 2.808 ms, which is 50 times faster than in the traditional mechanical detectors under investigation. Furthermore, through a precise analysis of yarn vibration patterns, it became possible to determine the distance from the sensor at which the break occurred. This analysis was conducted using the proprietary MRSCEK coefficient, which aggregates data obtained from six standard coefficients: mean, root mean square, standard deviation, crest factor, energy, and kurtosis. This information could potentially lead to the development of automated systems for removing breaks without human intervention in the future. Research efforts focused on analyzing the vibration signals received from yarns made with different linear densities. The results showed that such a system could effectively replace commonly used mechanical yarn break detectors and operate much faster.

Performance research and structure optimization of quartz-covered alumina high-strength wear-resistant yarn

Improved abrasion resistance and shear performance of alumina fiber yarns is crucial to the weaving process. Herein, a series of novel SiO2@Al2O3 single-layer and double-layer covered yarns were prepared by winding 48 tex quartz yarn on the outer layer of 120–600 tex alumina yarn with wrapping twist of 50–500 twists/m. Wear resistance, shear force, and tensile fracture properties of the covered yarn were tested and analyzed. Wrapping twist ranges from 50 to 400 twists/m, with increased wrapping twist improving the SiO2@Al2O3 covered yarn's breaking strength, shear force, and wear resistance. As wrapping twist ranges from 400 to 500 twists/m, uneven winding and wear of quartz yarn weaken the breaking strength, wear resistance, and shear properties of SiO2@Al2O3 covered yarn. SiO2@Al2O3 double-layer covered yarn exhibits superior shear force, wear resistance, and tensile breaking strength compared with its single-layer counterpart. In comparison with the initial alumina yarn, wear resistance of SiO2@Al2O3 covered yarn improves by 50%, whereas the maximum shear strength and tensile breaking strength increase by 125% and 15%, respectively. High-strength, wear-resistant SiO2@Al2O3 covered yarn is suitable for alumina fabrics and braid structures, and is expected to be widely used in aerospace and the high-temperature insulation industry.

Research on Shape Memory Behaviour of Rib Knitted Fabric from Wool Yarn Descaled by Ultrasonic Wave

Wool is a special material with the shape memory capability, so it can be used not only for apparel but also for functional applications such as protecting clothes and thermo-regulating clothes. However, wool fibers have a surface structure of overlapping cuticle cells known as scales which significantly affect fiber properties. This research investigated the appearance, strength, extension and the shape memory behavior of the wool yarn and also the wool knitted fabric before and after descaling its cuticle cells using calcium carbonate (CaCO3) powder with the concentration of 5 g/l, 10 g/l, 15g/l, and 20g/l in ultrasonic bath. The results showed that ultrasonic wave and abrasive calcium carbonate powder could reduce the size and the sharpness of wool scale. Wool yarn breaking strength and elongation tended to increase due to the increase of CaCO3 concentration, while the value of CV (%) decreased. The shape memory behavior was evaluated according to the change in length for the wool yarn, and the change in loop dimensions for the knitted fabric in different environmental humidity and temperature. Wool yarn descaled with CaCO3 powder showed more change in length in comparison to original yarn, but the change was a little bit of less than 3%. For the wool rib knitted fabric, the change in vertical direction was negligible, while the change in horizontal direction was significant, especially in the case of rib knitted fabric made of wool yarn descaled with CaCO3 powder. Wool yarn descaled showed a little change in length while the wool knitted fabric showed the more stable in shape by the course direction in comparison to those before descaling treatment.

Hybrid Oversampling and Undersampling Method (HOUM) via Safe-Level SMOTE and Support Vector Machine

The improvements in collecting and processing data using machine learning algorithms have increased the interest in data mining. This trend has led to the development of real-life decision support systems (DSSs) in diverse areas such as biomedical informatics, fraud detection, natural language processing, face recognition, autonomous vehicles, image processing, and each part of the real production environment. The imbalanced datasets in some of these studies, which result in low performance measures, have highlighted the need for additional efforts to address this issue. The proposed method (HOUM) is used to address the issue of imbalanced datasets for classification problems in this study. The aim of the model is to prevent the overfitting problem caused by oversampling and valuable data loss caused by undersampling in imbalanced data and obtain successful classification results. The HOUM is a hybrid approach that tackles imbalanced class distribution challenges, refines datasets, and improves model robustness. In the first step, majority-class data points that are distant from the decision boundary obtained via SVM are reduced. If the data are not balanced, SLS is employed to augment the minority-class data. This loop continues until the dataset becomes balanced. The main contribution of the proposed method is reproducing informative minority data using SLS and diminishing non-informative majority data using the SVM before applying classification techniques. Firstly, the efficiency of the proposed method, the HOUM, is verified by comparison with the SMOTE, SMOTEENN, and SMOTETomek techniques using eight datasets. Then, the results of the W-SIMO and RusAda algorithms, which were developed for imbalanced datasets, are compared with those of the HOUM. The strength of the HOUM is revealed through this comparison. The proposed HOUM algorithm utilizes a real dataset obtained from a project endorsed by The Scientific and Technical Research Council of Turkey. The collected data include quality control and processing parameters of yarn data. The aim of this project is to prevent yarn breakage errors during the weaving process on looms. This study introduces a decision support system (DSS) designed to prevent yarn breakage during fabric weaving. The high performance of the algorithm may encourage producers to manage yarn flow and enhance the HOUM’s efficiency as a DSS.

Improved YOLOv5s Fabric Defect Detection Algorithm Based on the Fusion of Global Attention Mechanism and Decoupling Head

During fabric production, machine malfunctions and yarn breakages can lead to defects, affecting product quality. Thus, fabric defect detection is crucial for quality control. Existing detection systems struggle with speed and accuracy, especially for small defects, due to the diversity of defect types and shapes. This paper introduces an improved YOLOv5s algorithm, YOLOv5s-GSD, which enhances detection performance by integrating a Global Attention Mechanism (GAM), the SIOU loss function, and a decoupling head. The GAM enhances focus on relevant features, improving detection accuracy; the SIOU loss function replaces the GIOU loss function to optimize the vector angle of regressions, enhancing convergence speed and accuracy; and the decoupling head separates classification and regression tasks, further improving detection performance. Experimental results show the improved algorithm achieves an accuracy of 97.6% and a recognition rate of 36 frames per second, effectively reducing the miss rate of small targets.

Highly Soft, Abrasion-Resistant, and Moisture-Absorbent Wool/PA56 Blended Yarns for Seating Fabrics.

Biobased nylon (PA56) not only has the same physical properties as nylon (PA6/PA66) but its production method is also more environmentally friendly. PA56 fabric has the advantages of moisture absorption, perspiration, high-temperature resistance, and flexibility, which have been widely studied by scientific researchers. Wool has the advantages of beauty, environmental protection, and anti-wrinkle. However, pure wool fabrics have low strength and are easy to shrink when washed, which has always been a problem. Hence, this work adopted the ring spinning method to prepare wool/PA56 blended yarn with wool content of 0, 10, 30, 50, 70, and 100 wt%. Thus, to examine the effects of different blending ratios and twists on yarn performance, PA56 was blended with wool. The results showed that findings indicate that yarn performance is influenced by both yarn twist and blending ratio. The yarn thickens and takes on more linear density as the blending ratio and yarn twist increase. As the wool ratio increases, the yarn's breaking stress and breaking strain decrease. It is obvious that the strength and elongation at break of pure PA56 yarn are 2.09 cN/Dtex and 33.92%, respectively. When the wool content was 100 wt%, the strength and elongation at break of the blended yarn were 0.66 cN/Dtex and 21.15%, respectively. With the amount of wool blending, the yarn hairiness index's H-value initially rises and subsequently falls. The percentage of blended wool reaches 50% at 2.14; less blending might exacerbate the yarn's stem, resulting in neps and unevenness features. The quality of the yarn improves as the blending percentage rises. The yarn has the advantages of resource saving, biodegradability, and environmental friendliness and has a broad application prospect in the automotive interior field.

Effects of Carbon/Kevlar Hybrid Ply and Intercalation Sequence on Mechanical Properties and Damage Resistance of Composite Laminates under Quasi-Static Indentation.

The investigation of damage development is essential for the design and optimization of hybrid structures. This paper provides a reference for the structural design of brittle-ductile hybrid LVI-resistant laminates through analyzing the damage development mechanism of carbon/Kevlar fabric-reinforced composite laminates. The effects of Kevlar fabric hybrid ply and intercalation on the damage development of carbon/Kevlar composite laminates under low-velocity impact (LVI) were investigated using quasi-static indentation (QSI). It was found that an increase in the Kevlar hybrid ratio significantly reduced the peak load and stiffness of these laminates (the maximum decreases in strength and stiffness were 46.03% and 41.43%, respectively), while laminates with identical hybrid ratios but different plying configurations maintained a comparable stiffness under QSI, with differences of less than 5%. Interestingly, Kevlar fibers exhibited irregular fractures as the yarn was splitting, while carbon fibers presented neat breaks, which indicated material-specific failure modes. Notably, the introduction of Kevlar hybridization beyond pure Kevlar configurations (KKKK) resulted in a decrease in the percentage of fiber damage (CCCC, CCCK, CCKK, and KCCK accounted for 80%, 79.8%, 70%, and 60% of fiber damage, respectively), attributed to an increase in resin cracks and lower levels of Kevlar yarn breakage. The internal damage diameter of specimens was accurately predicted from the diameter of visible damage on the QSI surface. Compared with CCCC and CCKK setups, which are affected by resin cracks formed via the carbon surface on the loading side propagating along the yarn direction (including the yarn settling direction), KCCK demonstrated less delamination between the first and second ply.

Comparison of constant spindle speed twisting technology and constant tension twisting technology of E‐glass yarn

AbstractThe rapid advancement of the electronics industry has continuously increased demands for the E‐glass yarn's quality and production capacity. The twisting and winding process stands out as a crucial step in E‐glass yarn production. Twisted bobbin yarns are produced separately using constant spindle speed technology and constant tension technology in order to address issues such as high yarn breakage rates and excessive yarn hairiness during twisting. By comparing the twisting tension, yarn breakage rates, and yarn hairiness between these two technologies, this study delves into the impact of twisting technology on E‐glass yarn quality and production capacity. The results indicate that, in comparison with constant spindle speed technology, constant tension technology reduces the unevenness ratio of twisting tension from 8.94% to 0.55%, decreases yarn breakage rates from 3.05% to 2.03%, reduces long hairiness by 20.3%, and reduces short hairiness by 25.1%. By reducing the spindle speed when the bobbin yarn's diameter increases, constant tension twisting technology reduces the unevenness ratio of twisting tension, yarn breakage rate, and yarn hairiness. These research findings lay the foundation for the development of high‐end E‐glass yarn products and carry significant practical value in improving yarn quality, enhancing production capacity, and reducing E‐glass yarn losses.Highlights The twisting and winding principle of E‐glass yarn is revealed. The relationship among four tensions in the twisting and winding process is clarified. The parameters for the constant tension twisting technology are developed. The measurement method for the twisting tension is improved.

Design of a Novel Creel Conditioning System for Circular Knitting Machines

Maintaining a certain humidity level of humidity in yarn packages and removing fibre fly from the environment is very important for production efficiency and product quality in textile mills. Humidity has a significant effect on the quality and efficiency of fabrics, especially those made from hydrophilic fibres. The high temperature and low humidity level in the factory environment results in lower yarn strength and higher yarn breakage. The solution is to provide optimum temperature and humidity levels through a central air conditioning system. However, conditioning the entire factory environment is an expensive approach and does not facilitate satisfactory production efficiency. In this study, a new creel system for circular knitting machines was designed to provide excellent yarn package conditioning. More efficient production and economical conditioning were achieved with this new creel system.

<i>In Situ</i> Measurement of Twist Propagation and Yarn Tension with Superconducting Magnetic Bearing Twisting Element for Ring Spinning Process

The twisting of yarn in one of the most widely used conventional ring spinning processes is based on the ring/traveler system. The existing limitation of productivity in the ring spinning process lies on the prevailing force relation between ring, traveler and yarn as well as the frictional heat between traveler and ring, principally in the ring traveler system. Recently, a frictional free twisting element based on a superconducting magnetic bearing (SMB) was developed to increase the productivity of ring spinning drastically, which was patented by ITM and Leibniz IFW Dresden. This SMB consists of a circular superconductor and a permanent magnet (PM) ring. In the superconducting state, the PM ring levitates and can freely rotate even up to an angular speed of 50.000 rpm. It is connected with the spindle via the yarn through a guide attached to the PM ring to impart yarn twist. Through the rotation of the PM ring, the twist propagates to the nip point of the delivery rollers. The twist propagation rate depends on different parameters, e.g., spindle speed, balloon geometry, and friction between yarn and yarn guides. A change in the level of twist affects the process, yarn tension, yarn breakage rate, and yarn properties. Hence, it is important to investigate the twist distribution to derive effective measures for improving the twist propagation especially at higher angular spindle speeds and thus eliminate weak points to increase process stability and yarn quality. The aim of these measurements is to analyze the twist distribution along the yarn path to understand the causes of yarn breakages. In this study, the yarn path was traced at different regions by in-situ measuring the helix angle of twisted yarn using a high-speed camera. From the recorded images, the number of twists per unit length was determined using the image processing software ‘Image J’. Thus, the measurement method allows a new insight into the problem of yarn breakages originating from twist propagation in order to take optimized measures at higher angular spindle speeds.

Computational modeling of the strength of staple yarn based on the random arrangement of fibers

Staple yarn is the basic element of most textiles, and its strength affects the performance and processing efficiency of the final textile products. Meanwhile, its strength is the combination of the resistance to breakage and slip of fibers in the yarn. In this paper, a computational model is proposed to predict the strength of staple yarn. The resistance to breakage and slip of each fiber were first computed based on the random arrangement of the fibers and the idealized yarn structure, and the strength was computed by identifying fiber breakage or slip in the yarn breakage zone. The reliability and applicability of the model were verified on viscose and polyester ring-spun staple yarns. The results show that the mean error of prediction is mostly less than 5%, indicating that the model has good accuracy and applicability; and the correlation coefficient R is mostly greater than 0.95, indicating that the predicted strength is in good agreement with the tested strength.

Six Sigma methodology implementation for minimising yarn breakages in the apparel industry

Six Sigma methodology implementation for minimising yarn breakages in the apparel industry

Features of the technology for producing combed yarn from medium-fiber cotton

The article examines the features of the technology of production of re-combed yarn from medium fiber cotton selection varieties. The experiments were carried out under production conditions on the Rieter E-66 combing machine. To determine the optimal technological parameters of the machine, a full factorial experiment was conducted to determine the unevenness of the 1-meter-long braid, the output of recombing tension, the staple length of the fibers in the strand, and regression equations were obtained. According to the results of the full-factor experiment, the improvement of the quality parameters of the recombing machine was achieved when the speed of the comb drum of the combing machine is 400 min-1, the distance between the lower jaw of the clamps and the comb segment is 0.2 mm, and the distance between the lower jaw of the clamps and the separating cylinder is 16.5 mm. According to the theoretical and experimental evaluations, using the optimal parameters of the high-speed combing machine, the cotton re-combed from the cotton fibers meeting all requirements was produced on the G-3 warped spinning machine of the Rieter company, with a drawing density of 14.8 tex (Ne 36). As a result of improving the physical and mechanical quality of spun yarn, the number of yarn breaks that damage 1000 yarns has decreased by 25%, and machine productivity has increased.

Experimental research and numerical simulation of the relationship between yarn tension and multi-balloon shape

Yarn tension during ring spinning is influenced by the shape of the balloon. With the high speed of ring spinning, the existing balloon control technology will have problems with yarn breakage caused by increased tension and yarn wear during the spinning process. Therefore, this article takes the naturally formed multi-balloon as the research object and analyzes the force of the yarn in the balloon section to establish the mathematical model of the steady-state balloon section. Then we selected the appropriate parameters to compare the balloon trajectory graph obtained by simulation and experiment, to verify the validity of the mathematical model. Finally, the relationship between the yarn tension and the number of balloon segments under different balloon heights and spindle speeds, and the conditions for the stable shape of multi-balloon are discussed. It was found that under different balloon shapes, increasing the number of balloon segments can effectively reduce the yarn tension at the yarn guide, and the stable conditions of balloons with different numbers of segments under certain process conditions. The findings are of great significance to the subsequent research on the technological parameters of low-tension spinning and the structural design of ring-spinning machines.

Multiaxial failure mechanism of 3D triple-twill warp-lining woven composites

3D triple-twill warp-lining woven composites (3DTTWLWC) has promising applications in many fields, but their multiaxial behavior is not clear. Herein, biaxial specimens of 3DTTWLWC are prepared and different experiments are performed. The results show that as the biaxial stress ratios (rbs) increases, the tensile/torsional stiffnesses and strengths decrease/increase and increase/decrease, respectively. Furthermore, under multiaxial-loading, the dominant damage pattern changed gradually from weft yarn breakage in the crack initiation zone to warp and binder yarn pullout in the failure zone. This work provides a reference for the structural design of 3DTTWLWC with significant engineering implications.

Characterization of viscoelastic properties of yarn materials: Dynamic mechanical analysis in the transversal direction

AbstractWarp knitting creates very challenging dynamics due to its high production speeds. On the one hand, this makes it method of choice for many products in various fields. On the other hand, not all materials are suitable for such high productivity. With the current generation of machines being limited to only achieve their maximum speed of around 4,400 min−1with highly elastic yarns, it is desired to gain a deeper insight into yarn behavior in such highly dynamic environments. Among other influences, resonance effects gain high significance as they may result in high loads on the used materials; therefore, yarn breakages interrupt the production and decrease the quality of the product. To extend the material choice, especially high-performance fibers, for high productivity, a deep understanding of the intrinsic properties of the yarn is required. In particular, the viscoelastic properties are of importance. This study proposes a method to determine these characteristics using the dynamic mechanical analysis method. For the purpose of finding the damping in the transversal direction to the yarn axis, the variant of free oscillation is chosen. For the trials, a high-speed camera is suspended above a testing rig. On this rig, a yarn sample is clamped and then displaced from its rest position. The resulting oscillation is recorded and later extracted from the video. From the decrement of the maxima of the amplitude and corresponding time intervals, the damping factor is determined. It decreases with higher initial deflection. Summarised the developed trial setup proved suitable for the determination of the viscoelastic properties in transversal direction.

Yarn breakage detection in ring spinning through ring temperature drop

Yarn breakage or ends-down in ring spinning adversely affects spinning efficiency. An ends-down event may continue for an extended period of time before it is detected and attended to. This study explored a novel approach to detect yarn breakage or ends-down in ring spinning, through changes in ring temperature after an ends-down. Numerical simulation and experimental verification were used to examine the ring temperature changes during the yarn breakage process. The results showed that higher ambient temperature, spindle speed and yarn count (tex) resulted in a higher ring temperature and a longer ring cooling time. But the rate of ring temperature decrease immediately after yarn breakage was quite high, dropping 50% between equilibrium and ambient temperatures in approximately 16 s for most spinning conditions. The model and results of this study offer the basis for a new yarn breakage detection option in ring spinning based on the temperature change of the ring.

Effect of woven yarn angle on the low‐velocity impact damage response of fibre woven thermoplastic composites

AbstractFibre woven thermoplastic composites (FWTC) are widely used in aerospace and other fields because of their excellent performance. During service, FWTC structures are inevitably subjected to low‐velocity impact (LVI), which can cause invisible damage and eventual failure of the material. At the moment, studies on FWTC mostly focused on the orthogonal woven yarns while there's few reports about the effect of the yarn angle changing on the woven material's LVI damage response. This study aims at the effect of yarn angle changing on the damage behaviour of FWTC. A method for preparation of nonorthogonal prepregs was proposed, by which FWTC laminates with different yarn angles (60°, 75°, and 90°) were prepared for LVI tests. The results show that the maximum impact displacement and the impact duration of the impactor decrease with the decrease of the yarn angle when the FWTC laminate is subjected to LVI, while the maximum impact force shows an increasing trend. This indicates that the smaller yarn angle causes the better load‐bearing capacity of the FWTC laminate under LVI conditions, while the orthogonal FWTC laminate is more ductile. The damage morphology indicated by the impact of the FWTC laminate are matrix cracks and yarn breaks, and the damage area increases with the decrease of yarn angle, where the damage of orthogonal laminate is more serious more concentrated. The results found in this paper can provide useful guidance for engineering applications and failure analysis of FWTC.

Structural design and mechanical properties of glass fiber weft-knitted biaxial tubular fabrics

In order to design glass fiber weft-knitted biaxial tubular (WKBT) fabric with the excellent dimensional stability and outstanding mechanical properties, six kinds of WKBT fabrics were prepared by four kinds of knitting structures (1 + 1 rib structure, face plating structure, back plating structure and face and back plating structure) and two kinds of stitch yarns (polyester and polytetrafluoroethylene fiber). The tensile properties, tearing properties and bursting tearing properties of WKBT fabrics with different binding tightness were investigated. The results showed that the failure of WKBT fabric was composed of the breakage of insertion yarns and the breakage of knitting structures. The tightness of knitting structures have significant effect on the mechanical properties of WKBT fabric. Compared with 1 + 1 rib structure, the plating structure affects the mechanical properties of WKBT fabrics by improving the weft density, binding tightness and dimensional stability. The kind of stitch yarn is another factor that affects the mechanical properties of WKBT fabrics.

An analogical method for evaluating ring performance based on quality and production parameters

This study was carried out to determine the best ring size for a certain yarn count. In a ring frame with three separate rings of varying sizes, 20s/1 kW yarn was created. The spinning method used the same ring speed, twist, ring traveller, and spacer but three distinct rings with diameters of 38 mm (Ring- A), 40 mm (Ring- B), and 42 mm (Ring- C). Then, under the same testing conditions, ten samples of each yarn were examined by Uster Evenness Tester (UT-6) and compared to determine the best one. The “Ring- C″ production yield was 0.22% and 1.34% greater than the “Ring- B″ and “Ring- A″ yields, respectively. Yarn breakage for “Ring- C″ was 47.78% and 200% greater than for “Ring- B″ and “Ring- A,” respectively. Yarn unevenness for “Ring- C″ was found to be 4.15% and 4.14% higher than “Ring- B″ and “Ring- A,” imperfection of yarn produced by “Ring- B″ was 18.54% and 3.47% lower than “Ring- C″ and “Ring- A,” and tenacity of yarn produced by “Ring- B″ was 3.35% and 0.64% higher than “Ring- C″ and “Ring- A.” “Ring- C″ yarn hairiness was 10.63% and 12.31% higher than “Ring- B″ and “Ring- A″ yarn hairiness, respectively. According to the study of the tested report, yarn generated from “Ring- B″ delivered optimized results in terms of both quality and output. Ring “Ring- B″ had a lower production loss than Ring “A" but a higher loss than Ring “C.” Also, the hairiness of yarn made from “Ring- B″ was remarkably similar to yarn made from “Ring- A."