Splice Clearing 5

Main Contents

5. Splice Clearing....................................................................................... 5.1

5.1 Introduction .................................................................................................................................. 5.1

5.2 Scatter plot of splices ................................................................................................................. 5.1
5.3 Splices .......................................................................................................................................... 5.3
5.3.1 Visual appearance ......................................................................................................................... 5.3
5.3.2 Practical example .......................................................................................................................... 5.4
5.3.3 Wet Splicing ................................................................................................................................... 5.6
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5.4 Splice classification of the USTER QUANTUM 3 .................................................................... 5.6
5.5 Clearing limits for splice clearing (Jp and Jm)......................................................................... 5.7
5.5.1 Standard way of optimizing clearing limits: Manual clearing limits entry ...................................... 5.7
5.5.2 Setting a smart clearing limit for splices (Jp/Jm) ........................................................................... 5.8
5.6 Upper yarn detection (U) ........................................................................................................... 5.11
5.7 Minimizing the number of splices ............................................................................................ 5.12
5.7.1 Critical items which affect the number of splices......................................................................... 5.12
5.7.2 Mean time between two splices................................................................................................... 5.13
5.7.3 Field test ...................................................................................................................................... 5.14
5.7.4 Relationship between the productivity on winding machines and splices ................................... 5.15
5.8 Impact of clearing limits on splice clearing ............................................................................ 5.17
5.8.1 Clearing limit closer than the average splice quality ................................................................... 5.17
5.8.2 Single splice positions are defective ........................................................................................... 5.18

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5. Splice Clearing
5.1 Introduction

A splice, also called yarn joint, has the purpose to join two ends of a yarn as a result of yarn fault re-
moval on winding machines and bobbin changes during the winding process. This means: when a
detected fault is eliminated, the resulting yarn ends are pieced together by an automatic splicing de-
vice [1]. In the past, it was common practice to knot yarns together, but the knots were significant in
appearance, a source of weakness and could also lead to problems in subsequent processes. Nowa-
days, yarns are spliced using mechanical splicers, air-splicers, water-splicers, thermo-splicers, etc.
which produce a joint that is usually at least 70% of the strength of the mean yarn strength, and gen-
erally less than 130% of the thickness of the parent yarn. The splice efficiency is used as a measure
of the spliced part of the yarn, expressed as percentage strength of the reference yarn. The adoption
of splicing has greatly reduced problems in weaving, knitting, and dyeing [2].

A yarn must have a certain minimum tensile strength and a minimum elongation in order to stand up
to the processes subsequent to spinning. This is also and especially valid for splices that join together
two ends of a yarn. Since an average count ring-spun yarn can have more than 100 splices over a
length of 100 km, it is important to monitor the parameters of the splices carefully.

Besides the quality aspect that needs to be fulfilled by the yarn, its processing quality depends to a
certain extent also on the quality of the splices. Today, approximately one splice per kilometer has to
be expected in a cone. Considering the costs for a yarn break in knitting, warping, sizing or weaving,
the splices play an important role in this respect as well. The number of splices must be kept at a low
level, but the potential weak places must have the highest strength possible. This is only possible by
checking the strength of the splices regularly by means of an instrument.

5.2 Scatter plot of splices

The USTER® QUANTUM 3 interprets and displays the splice characteristics with the help of a scatter
plot. It is the graphic representation of the thickness and length within a classification matrix. Each
splice is marked with one dot representing the most significant deviation within the so called splice
window. The vertical scale represents the yarn mass or diameter increase and decrease of a splice
and the horizontal axis represents the splice length in cm. Fig. 5-1 shows a scatter plot with splices as
seen by the USTER® QUANTUM 3, with all the splice recorded (green dots), the actual clearing limit
and the area of the disturbing splices (red dots) which exceed the maximum and minimum admissible
splices.

The scatter plots are used to visualize the optimum clearing limits for both the Splice Clearing
(Jp/Jm), and for such events the graphical display of a scatter plot matches the demands of the
customers best. The scatter plot for Splice Clearing (Jp/Jm) represents the classified splices. The
USTER® QUANTUM 3 classifies the thickest (Jp, Fig. 5-1, red circle) and thinnest (Jm, Fig. 5-1, blue
circle) event for every splice and show them on the scatter plot. The active clearing limit of the Jp
splice clearing limit is highlighted with red color on the setting page (Jp = joint, positive).

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Fig. 5-1 Splice distribution

In the display main menu, it is possible to display either scatter plot of splices alone (Fig. 5-2) or to-
gether with the scatter plot of disturbing thick and thick places (NSLT) (Fig. 5-3). Fig. 5-3 shows a
regular distribution of splices (dark green dots) together with the scatter plot of the thick and thick
places (light green dots). This combined scatter plot is a very helpful tool to show the localization and
the distribution of splices compared to the remaining thick and thin places in the yarn. With the help of
this combined graph, it is very easy to compare the splices to the natural events in the yarn and to
avoid unnecessary splices because it makes no sense to replace a small fault by a bigger splice.

Fig. 5-2 Scatter plot of splices with the Fig. 5-3 Scatter plot of splices and thick/thin
clearing curves for thick/thin places and places together
splices

The scatter plot of splices demonstrates the performance of the splicer and shows the position of the
outliers.

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Examples of various scatter plots for splices.

Fig. 5-4 Optimum clearing curve for splices Fig. 5-5 Clearing curve for splices with an open
setting for NSL T clearing

Fig. 5-6 Clearing curve for splices too narrow in Fig. 5-7 Clearing curve for splices closer than
the domain of thick places NSL T limits

Splices beyond the clearing curves (red dots) have to be repeated. The scatter plots show the popula-
tion of the splices. Based on the scatter plot it is easy to recognize the outliers and to set the clearing
curve for splices.

5.3 Splices

5.3.1 Visual appearance

Splices are almost invisible in contrast to knots which used to be yarn joints in the past. Various inves-
tigations have shown that the strength of the splices is critical in order to obtain a suitable splice in
terms of size, a compromise may need to be reached between splice strength and appearance.

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A well spliced joint has a mass which is 20 to 30% higher than the yarn over a length of approximately
15 to 60 mm, and an average strength of around 80% or more of the mean yarn strength [1]. The var-
iation of strength should also be low. Fig. 5-8 shows pictures of several splices.

Fig. 5-8 Picture of several acceptable splices

5.3.2 Practical example

In a spinning mill the splices of 20 positions of a winding machine were tested. On each position, five
splices were tested. The yarn type was Ne 30, carded, 100% cotton. Fig. 5-9 and Fig. 5-10 show the
results of this trial. The blue dots indicate the test results of the splices, whereas the colored lines
show the test results (minimum, maximum and average values) of the same yarn without a splice
measured also on the USTER® ZWEIGLE SPLICE TESTER as the reference (ten measurements of
the reference yarn). The minimum breaking force of the reference yarn was 222 cN, the average
breaking force was 261 cN and the maximum breaking force was 302 cN. In regard to the elongation,
the reference yarn had a minimum breaking elongation of 3.95%, an average breaking elongation of
4.66% and a maximum breaking elongation of 5.28% (Fig. 5-10).

400

350

300

250
Force [cN]

200

150

100

50

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

Force of splices Minimum Reference Maximum Reference Average Reference

Fig. 5-9 Breaking force of splices, ring-spun yarn, compared with the mean strength of the yarn

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10

7
Elongation [%]

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

Elongation splice Minimum Reference Maximum Reference Average Reference

Fig. 5-10 Breaking elongation of splices, ring-spun yarn

The numeric test results were as follows:

Reference yarn Splice

Yarn type Ne 30, 100% CO, carded Ne 30, 100% CO, carded

Strength [cN] 261 200

Variation of the strength [%] 9.91 23.0

Elongation [%] 4.66 4.87

Variation of the elongation [%] 10.16 16.88

Table 5-1

Out of this data, the following conclusions can be drawn. The splices only reach an average breaking
force of 76% compared to the regular (reference) yarn. As a rule of thumb, the strength of a splice
should reach at least 70% of the strength compared of a regular yarn. The breaking elongation, on the
other hand, improved slightly. Regarding the variation of the strength and the variation of the elonga-
tion it can be observed that it is much higher compared to the reference yarn. This is an important
quality parameter, as the high variation of the breaking force will lead to problems later on in subse-
quent processing. The lowermost breaking force of a splice was measured at 83 cN, and the strong-
est splice was measured with 295 cN. This is a huge difference that must be put under control.

Therefore, it is recommended to check the splice mechanism of this winding machine and to modify
the settings in order to reach higher strength values and lower variations from winding position to
winding position.

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5.3.3 Wet Splicing

The USTER® QUANTUM 3 optical clearer can be used with wet splicer without any restrictions. The
capacitive clearer can be used with restrictions depending on the amount of water sprayed. Please
contact USTER® for support.

For the capacitive clearer the combination with Foreign Matter option, i.e. either C15/F30 or C20/F30,
is required. There is a special setting for these clearers (Fig. 5-11) and the splice will be cleared opti-
cally and needs an optical setting.

Fig. 5-11 Wet splice

For adjusting the splice clearing it is recommended to use JP adjust to NSL T at Level 20% and to
adjust the setting U% at 80%.

5.4 Splice classification of the USTER® QUANTUM 3

The USTER® QUANTUM offers a unique feature, which is the splice classification. Each splice is
measured, classified, and marked with a green or red square in the scatter plot depending on the
splice settings. Thus, it is possible to check every winding position of a winding machine in order to
see if the splices fulfill the requirements with regard to the appearance (Fig. 5-12).

Fig. 5-12 Display of splices (left) and splice classification (right)

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Meaning of the red rectangles: The size of the splice or mass increase has exceeded the set splice
limits. The splice formation has to be repeated. The USTER® QUANTUM 3 classifies the thickest (Jp)
and thinnest (Jm) event for every splice.

The splice channel J checks the yarn joint when passing the clearer just after it has been made by the
splicer device. The evaluation of J is similar to the NSLT thick and thin places evaluations. Splice
check Jp /Jm detects yarn joints which are “too thick” or “too thin”.

5.5 Clearing limits for splice clearing (Jp and Jm)

5.5.1 Standard way of optimizing clearing limits: Manual clearing limits entry

Fig. 5-13 shows the clearing limit as shown in the setting window of the Control Clearing Unit. The
USTER® QUANTUM 3 allows the determination of the splice clearing limits by placing a maximum of
8 set points Jp1 to Jp8 /Jm1 to Jm8. In Fig. 5-13, we can see 5 setting points (red rectangle) and the
clearing limit for splices. By this setting method the effects of a change of the parameters on the clear-
ing limit can be demonstrated directly.

As soon as we enter new values at set point, the next set point will appear until we reach the 8th set
point. This means after we enter the values for Jp1 (or Jm1), set point Jp2 (or Jm2) will appear and it
will continue the same way.

Fig. 5-13 Clearing limits on the screen of the Control Clearing Unit, manual entry

Set points have two parameters. These are: sensitivity (%) and reference length (cm).

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Sensitivity
The sensitivity (%) is a parameter for the clearing limits of the corresponding fault channel. The sensi-
tivity setting shifts the clearing limit upwards (less sensitive) or downwards (more sensitive,
Jp1 = 300%, Fig. 5-13).

Reference length
The reference length (cm) is a parameter for the clearing limits of the corresponding fault channel and
shifts the clearing limit to the right (less sensitive) or to the left (more sensitive, Jp1 = 0.6 cm, Fig.
5-13).

5.5.2 Setting a smart clearing limit for splices (Jp/Jm)

With the USTER® QUANTUM 3 splice clearing became much easier. A smart possibility offered by
the system is to synchronize the splice settings to the thick and thin place (NSLT) settings to avoid
bad splices being passed. The splice clearing curve could be selected ideally as same as the NSLT
clearing limits.

Similar to the YARN BODYTM, after running only a few kilometers of yarn, the first impression of the
scatter plot and the events will appear. In order to see the scatter plot, the user should press the scat-
ter plot key (Fig. 5-14). Besides the scatter plot, also the scatter plot of the cut faults and remaining
events, and the number of expected fault cuts per 100 km together with the used setting limits will
appear directly on the same setting page (Fig. 5-14). It is recommended to have at least 100 splices
before making any fine tuning in the splice clearings settings.

Pressing key presents

• Scatter plot of the cut faults and

remaining events.
• Number of expected fault cuts /
100 km

Clearing limit

Red dots = cut yarn faults.

Green dots = remaining events

Fig. 5-14 Jp settings adjustment to the scatter plot, thick places

For highest quality requirements the Jp, Jm setting can even be set up to 5 to 10% below the NSLT
clearing limit (red circle). Good splices set the Jp splice clearing curve below the NSL thick places
clearing curve (more sensitive setting) and on the contrary bad splices set the Jp splice clearing curve
above the NSL thick places clearing curve (less sensitive setting, Fig. 5-14).

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The same rule is also valid for Jm splice clearing curve; there the Jm clearing curve will be set below
or above the T thin places clearing curve according to the good or bad results. If this will result in too
many Jp or Jm cuts then the rogue splicers should be identified and fixed. F and PP faults are also
detected during splice check (Fig. 5-15).

Fig. 5-15 Jm settings adjustment to the scatter plot, thin places

Splices are displayed together with all the other yarn faults of the machine, of a group or of a winding
position. It can be switched from absolute values to values per 100 km.

Fig. 5-16 Jp/Jm yarn fault classification per winding position

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Recommendations:
The new setting possibilities will help to ensure that the splice should always be better than the re-
moved yarn fault. Depending on the mechanical settings of the splicer, we recommend to start with
the splice adjusted to the thick place (NSL) and thin place (T) limits. For high quality requirements we
also can use a setting closer than the clearing limits. This depends on the accepted Jp/Jm cut level /
100 km and of course of the splice quality possible.

Splices are displayed together with all the other yarn faults of the machine, of a group or of a winding
position (Fig. 5-17, red rectangle). In Fig. 5-17, the splice failure ratio (JR) has also been shown (Blue
rectangle). Splice failure ratio (JR) measures the number of cut joints compared to the passed ones. It
is the relation between total splices and splice cuts (Jp+Jm). In this example, the splice failure ratio is
equal to 3.4. This splice failure ratio as displayed at the CCU will always refer to the last 100 events
only.

Fig. 5-17 Jp/Jm yarn fault registration

In order to find rogue splicers, the user should check the machine summary report to find the bad
splicer. In the following example it is winding position no. 9 with a splice failure ratio of 33.3%. The
mean value is 12.44% (Fig. 5-18).

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Fig. 5-18 Machine summary display /JR Splice failure ratio

5.6 Upper yarn detection (U)

The “upper yarn” feature avoids that a double threat is accidentally taken from the package above the
clearer (Please consult Chapter 11).

Settings (Fig. 5-19):

For capacitive clearers: 80%
For optical clearers: 60%

Fig. 5-19 Upper yarn detection (U)

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5.7 Minimizing the number of splices

5.7.1 Critical items which affect the number of splices

The number of splices depends on the selected number of cuts to eliminate disturbing faults and the
number of joints necessary to process bobbins into a cone.

There are experience values available for yarn clearers on winding machines to understand the re-
placement of disturbing faults by splices. The relationship between the bobbin size, the number of
cuts and the yarn count is explained in Fig. 5-20. This figure shows the number of splices required if
the yarn clearer cuts 20 disturbing thick and thin places, 20 colored foreign fibers and 2 polypropylene
fibers.

No. of splices
per 100 km

140

92g
120

100
57g

80
40g

60
Bobbin changes

Polypropylene fibers
40
Colored foreign fibers

20
Disturbing thick and thin places

0 “Natural end breaks”

6 12 20 30 60 120 Nec
100 50 30 20 10 5 tex

Fig. 5-20 Number of splices for a given number of cuts

The average yarn mass of a fine yarn bobbin is 40 g. The mass of a bobbin in the medium count
range is approximately 57 g and 92 g within the coarse count range. Fig. 5-20 shows that the number
of splices required per 100 km also depends on the count and the weight of the bobbin.

As already mentioned, the disturbing yarn faults have to be eliminated on the winding machine and
replaced by a splice. The splice, however, should no longer be disturbing for the human eye. There-
fore, the splice can be checked by the yarn clearer (Fig. 5-21) and should be below the clearing
curve.

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Fig. 5-21 Monitoring of splices with the USTER QUANTUM 3

5.7.2 Mean time between two splices

It is not only the number of splices which needs our attention, but also the mean time between two
splices. If we are not careful in selecting the optimum clearing curve, the efficiency of the winding ma-
chine may collapse.

Table 5-2 shows the conditions on a winding machine when processing a 100% cotton yarn, Ne 30,
carded, winding speed 1400 m/min. Figures per 100 km of yarn.

Bobbin changes 20
‘Natural’ end breaks 2
Thin and thick places 21
Colored foreign fibers 18
Polypropylene fibers 2
Total number of splices 63 Table 5-2
Mean time between two
Mean time between 2 splices per winding position 1.13 min splices

The total run time of the machine to produce a yarn length of 100 km is 71.4 min at a winding speed
of 1400 m. With a total number of 63 splices, the mean time between 2 splices is only 1.13 minutes.
With a higher number of cuts, the mean time between splices would drop below one minute. This,
however, can be considered as a critical limit. Therefore, it is beneficial for the mill to select the clear-
ing curves carefully for disturbing thick places, thin places and foreign fibers.

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5.7.3 Field test

The USTER® QUANTUM 3 has to fulfill more and more tasks. On one hand the spinning mill has to
eliminate disturbing thin places, thick places, colored foreign fibers and polypropylene fibers and has
to replace them by a splice. In addition, the splicer of the winding machine has to produce splices at
the end of each bobbin. On the other hand the clearer should not influence the efficiency of the wind-
ing machine too much. The following is a study to demonstrate the critical cut rates of a clearer by
means of the mean time between splices MTBS.

Conditions:
Yarn Ne 30 (20 tex), yarn weight per bobbin 57 g, yarn length per bobbin 2850 m
Winding speeds: 800 / 1000 / 1200 / 1400 / 1600 m/min
Number of splices according to Table 5-3.

Reasons for splices Conditions

1 2 3 4 5 6 7 8

Bobbin changes 34 34 34 34 34 34 34 34

"Natural" end breaks 4 4 4 4 4 4 4 4

Thick and thin places 10 20 30 40 50 60 70 80

Colored foreign fibers 10 20 30 40 50 60 70 80

Polypropylene fibers 5 5 5 5 5 5 5 5

Number of splices 63 83 103 133 153 173 193 213

Table 5-3 Number of splices, conditions 1 to 8

Mean time between splices MTBS

Winding speed Winding time (under the conditions mentioned above)

1 2 3 4 5 6 7 8

800 m/min 125 min/100 km 2.08 1.51 1.21 0.94 0.82 0.72 0.65 0.59

1000 m/min 100 min/100 km 1.59 1.20 0.97 0.75 0.65 0.58 0.52 0.47

1200 m/min 83 min/100 km 1.32 1.00 0.81 0.62 0.54 0.48 0.43 0.39

1400 m/min 71.4 min/100 km 1.13 0.86 0.69 0.54 0.47 0.41 0.37 0.34

1600 m/min 62.5 min/100 km 0.99 0.75 0.61 0.47 0.41 0.36 0.32 0.29

Table 5-4 Mean time between splices MTBS at conditions 1 to 8

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Fig. 5-22 Mean time between splices

Reading example, Fig. 5-22: At condition 2 the mean time between splices already drops below 1
minute if the yarn speed exceeds 1200 m/min.

5.7.4 Relationship between the productivity on winding machines and splices

The adjustment of the clearing limits is not only improving the quality level of the yarn. But in all cases
the clearer should only remove the disturbing faults. The result is: optimum quality with less number of
cuts and splices. By only making the right cuts one can optimize quality and productivity.

It has been proven that the performance of the clearer (amount of cuts) is responsible for changing
drastically the winding machine productivity. In Fig. 5-23, the relationship between the productivity on
winding machines and splices can be seen. The red line is for yarn count Ne 50 and the blue line is
for yarn count Ne 30. Fig. 5-23 shows that 70 splices per 100 km means a productivity level of 79%
for yarn count Ne 30 and a productivity level of 81% for yarn count Ne 50. Speed: 1400 m/min.

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Table 5-5 shows an example of a winding productivity calculation.

Winding Count Bob- Fault cuts Bobbin Winding Formation Bobbin Total Total Total Winding
speed [tex] bin [1/100km] changes time for of a splice change duration duration for duration efficiency
[m/min] weight [1/100km] 100 km [min] duration for fault bobbin for stops [%]
[g] without [min] elimina- changes [m]
splices tion [min] [min]
[min]

12 tex
1400 60 20 20 71,43 0,18 0,22 3,6 4,40 8,0 88,8
(Ne 50)

12 tex
1400 60 70 20 71,43 0,18 0,22 12,6 4,40 17,0 76,2
(Ne 50)

20 tex
1400 60 20 33,3 71,43 0,18 0,22 3,6 7,33 10,9 84,7
(Ne 30)

20 tex
1400 60 70 33,3 71,43 0,18 0,22 12,6 7,33 19,9 72,1
(Ne 30)

Table 5-5 Example of a winding productivity calculation

Fig. 5-23 is a graphical evaluation of Table 5-5.

Fig. 5-23 Relationship between yarn clearing and productivity: splices and winding machine efficiency

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5.8 Impact of clearing limits on splice clearing

As a rule it is given that the dimension of a splice replacing a defect should never be more significant
than the defect taken out. It can happen that by only optimizing the clearer settings based on the
YARN BODYTM, the settings tend to be adjusted quite close to the yarn.

If the ability of splicing device is not as good as required for such a close limit it will increase the num-
ber of splice cuts. This effect will also be reflected by the splice failure ratio.

5.8.1 Clearing limit closer than the average splice quality

If the splice failure ratio becomes high for all positions in a group the splice setting itself has to be
controlled.

It may be required to even open the clearing limits again to a certain extend to reduce the number of
splice cuts. The USTER® QUANTUM 3 can display both, the scatter plot of splices as well as the
scatter plot of the yarn within the same screen. This tool can help to understand this effect.

Fig. 5-24 Relationship between yarn clearing and productivity: splices and winding machine efficiency

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5.8.2 Single splice positions are defective

If only single positions have a high Jp/Jm cut level the conditions of the single device has to be
checked. Such single positions showing excessive cuts might not increase the average level of splic-
es too much, but can spoil the whole production. The display of the splice failure ratio in the cut over-
view as well as the graphical summary of the whole machine gives a very good overview for spindles
with low performance splicing devices.

Fig. 5-25 identification of winding positions using the display of splice failure ratio

Reasons for bad splicers can be:

• Blocked suction or blowing device
• Use of wrong splice elements
• Worn out knives or splice tubes

Recommendation: To find the right balance between an optimal clearing limit and the performance of
the splicers, the scatter plot with display of J as well as NSL T will be a big help. It cannot be recom-
mended to keep a tight clearing limit for NSL t and open the splice limits to reduce the number of
splice cuts.

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