Count variations 4

Main Contents

4 Count variations .................................................................................... 4.1

4.1 Introduction .................................................................................................................................. 4.1

TM
4.2 Definition of the YARN BODY for long-term variations (C and CC faults) ......................... 4.1
4.3 Count deviations ......................................................................................................................... 4.3
4.3.1 Determination of the mean value of a yarn ................................................................................... 4.3
4.3.2 Purpose of yarn count deviation monitoring .................................................................................. 4.3
4.3.3 Monitoring of yarn count deviations during start-up in the C – channel ........................................ 4.4
4.3.4 Monitoring of the yarn count while winding with the CC-channel .................................................. 4.5
4.4 C and CC settings ........................................................................................................................ 4.6
4.4.1 Yarn count deviations at start up (C) settings ............................................................................... 4.7
4.4.2 Setting a smart clearing limit for yarn count monitoring (CC) ........................................................ 4.9
4.5 Calculation of yarn count deviations ...................................................................................... 4.12
4.5.1 Determination of count deviations with the clearer installation ................................................... 4.13
4.5.2 Calculation of the count deviations of wrong bobbins (capacitive measurement) ...................... 4.14
4.5.3 Calculation of count variations of wrong bobbins – optical measurement .................................. 4.15
4.5.4 Calculation of count variation of wrong bobbins with a diagram ................................................. 4.16
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4.5.5 Relationship between the mass and diameter deviation with the USTER Calculator ............... 4.17
4.6 Example for the setting of the C-channel ............................................................................... 4.18
4.7 The effect of count deviations on the fabric appearance ...................................................... 4.19
4.7.1 Mixing two different yarn counts .................................................................................................. 4.19
4.7.2 Reasons and measures to minimize count variations ................................................................. 4.23

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4 Count variations
4.1 Introduction

Deviations of the yarn count within a yarn lot lead to high costs for complaints. The fact that the faulty
yarn deviates from the nominal count can cause quality problems in the end product. The reasons for
count variations are diverse:
• Deviations by mixing in wrong bobbins
• Peeled-off or uneven rovings can lead to significant count deviations within a bobbin
• Missing sliver from a finisher drawframe without an autolevelling system

This demands a reliable monitoring of the yarn count on one side, but also its precise setting, which is
in accordance with the quality requirements of the yarn. This can be done in many ways. In the follow-
ing, two possibilities are described:
• The C-channel monitors the yarn count in the start-up phase after the splicing process. During
this phase, mainly bobbins with the wrong count are registered, and the winding position must be
stopped with the corresponding alarm functions. After the start-up phase, the C-channel is not ac-
tive anymore. This procedure allows the choice of very sensitive settings, which are adjusted to
the special circumstances of the start-up phase of the winding position.
• The CC-channel monitors the yarn count over the whole winding process. It is also possible to
monitor very long yarn faults with the CC-channel dependent on the choice of the settings.

4.2 Definition of the YARN BODYTM for long-term variations (C and CC faults)

The "YARN BODYTM" represents the nominal yarn with its tolerable, frequent yarn faults. YARN
BODYTM is a new yarn characteristic, and we know from the experience so far that the YARN BODYTM
changes according to the raw material and the spinning process. By analyzing the shape of the yarn
bodies out of different raw material varieties and process changes, we can discover patterns, and
build up references. Based on the references, the operator can identify changes. The YARN BODYTM
becomes always wider in the direction of the short yarn events, e.g. short faults occur more frequent-
ly. On the contrary, the YARN BODYTM becomes smaller in the direction of the long yarn events.

The USTER® QUANTUM 3 interprets and displays the yarn characteristics with the help of the YARN
BODYTM. The YARN BODYTM is a great tool to help finding the optimum clearing limits for thick plac-
es (NSL), thin places (T), yarn count deviations (C) and (CC).

The YARN BODYTM for CC is composed of two parts:

• Dark green area representing the real YARN BODYTM
• Light green area representing YARN BODYTM variations

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The YARN BODYTM for C is composed of two parts (Fig. 4-1):

• Dark green line representing the real YARN BODYTM.
• Light green line representing YARN BODYTM variations.

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Fig. 4-1 YARN BODY display for C the reference length can be defined between 2 to 100 m

The vertical scale represents the yarn mass or diameter increase and decrease, and the horizontal
axis represents the fault length in meter.

Fig. 4-2 represents the YARN BODYTM for CC-fault. In Fig. 4-2 the green shaded area represents the
YARN BODYTM for medium and long-term variations (2 to 12 m).

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Fig. 4-2 YARN BODY display for medium and long-term variations (CC faults), defined from 2 to 12 m

The vertical scale represents the yarn mass or diameter increase and decrease, and the horizontal
axis represents the faults length in meter.

Since both dark and light green areas together constitute the YARN BODYTM, it is recommended that
the clearing curve should not touch the YARN BODYTM. If the clearing limit is laid within these green
areas, the cuts will increase significantly and the productivity will drop.

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4.3 Count deviations

4.3.1 Determination of the mean value of a yarn

The pre-condition for an exact monitoring of yarn count deviations is the correct determination of the
nominal yarn count. With the command "Start article" the parameters of C and CC are switched to a
less sensitive fixed value in order to avoid wrong cuts during the calibration process. After the start-up
of the winding position, each sensor determines the mean value for the running yarn and forwards it
to the Central Clearing Unit. The Central Clearing Unit (CCU) calculates the mean value from all the
transmitted values and sends it back to the sensors.

4.3.2 Purpose of yarn count deviation monitoring

Deviations of the yarn count within a yarn lot lead to high costs for complaints. The fact that the faulty
yarn deviates over several meters or even longer from the nominal count can cause quality problems
in the end product.

This demands a reliable monitoring of the yarn count on one side, but also its precise setting, which is
in accordance with the quality requirements of the yarn.

Fig. 4-3 shows the possibilities for yarn fault monitoring, if the fault channels N, S, L, C and CC are
active.

Fig. 4-3 Clearing limits N, S, L, T, C+, C-, CCp and CCm

One important factor to be considered is the relation between reference length for the C and CC
channel and the variation of the values. In general as shorter as the reference is set as higher is the
resulting variation of the results.

For the setting it has to be considered that as longer the reference length is set as closer a +/- limit ca
be set. Fig. 4-3a is giving a schematic illustration of this effect.

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Fig. 4-4 Impact of reference length and variation

4.3.3 Monitoring of yarn count deviations during start-up in the C – channel

Objective
The recognition of count deviations after the splicing process must be carried out very quickly, before
too much yarn is wound on the cone. The pre-conditions during the start-up phase are not always
perfect for a very sensitive monitoring. Therefore the monitoring must be carried out over a certain
yarn length, in order to avoid wrong cuts. All modern winding machines are able to remove detected
count deviations by setting a reference length on the clearer.

Count variations in the start-up phase must be monitored with the C-channel. The thresholds for the
clearer are set with the following parameters:
• Cp sensitivity setting for the detection of yarn diameter or mass increases
• Cm sensitivity setting for the detection of yarn diameter or mass decreases
• Reference length can be set between 2 and 100 meter

The choice of the thresholds depends on different factors and must be adjusted to the conditions of
the mill:
• the produced yarn counts of the spinning mill
• the evenness of the yarn
• the possibilities of the winding machine to determine the suction length

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Function
With each start-up, the C-channel monitors the yarn over the set reference length. The sensor
measures the mean value over this length. If the mean value exceeds the above limits, a cut follows.

Yarn suction after a C-cut / Machines with fault-related yarn suction

Up-to-date winding machines provide measurable, fault-related yarn suction. The sensor transmits the
length of a Cp or Cm cut to the processor of each individual winding position and determines the
length to be sucked-off.

As deviations from the nominal count can be calculated more precisely over a larger reference length
it is recommended to choose the cut length on machines with a fault related yarn suction as long as
possible. However, one has to pay attention that no back-windings occur during the suctioning of the
yarn. In practice, lengths of 6 to 8 meters proved to show the best results.

For very critical applications lengths of 12 to 20 m are recommended.

4.3.4 Monitoring of the yarn count while winding with the CC-channel

Objective

• The reasons for deviations from the yarn count are numerous and vary from mill to mill. In the
end product, such events are only disturbing because of their length.
• By the draft, a faulty deviation can consists of several short, subsequent deviations, which are
only disturbing as a whole in the end product.

The recording of count variations and very long yarn faults takes place in the CC-channel, even when
they are interrupted by normal pieces of yarn. The yarn is monitored with two independent clearing
limits. The parameters for the clearer are given with the following settings:
• CCp sensitivity setting for the monitoring of mass and diameter increases
• CCm sensitivity setting for the monitoring of mass and diameter decreases
• Reference length is set for different length classes between 2.0 and 12.0 meters

Function
In contrast to the C-channel, the CC-channel is active over the whole winding length. Therefore, a
different kind of signal evaluation is applied. A mean value is continuously calculated. Short drops of
the yarn count have only a minor effect on the total result of the continuous mean value. If the contin-
uous mean value exceeds the above set sensitivity, a CC-cut is triggered.

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Fig. 4-5

Yarn suction after a CC-cut / Machines with fault-related yarn suction

Modern winding machines provide a measurable, fault related yarn suction. The winding position gets
the information from the yarn clearer, how much yarn has to be sucked-off before the splice is carried
out.

4.4 C and CC settings

The C-channel monitors the yarn count in the start-up phase after the splicing process. After the start-
up phase, the C-channel is not active anymore. As already known from USTER® QUANTUM 2, the C-
channel can be set for one reference length and a plus (Cp) and minus (Cm) limit.

The CC-channel monitors the yarn count during the whole winding process. Depending on the setting
long yarn faults with a small mass or diameter increase can be detected. This CC-channel is able to
detect and remove count variations at different cut length between 2 m and 12 m.

For the CC-channel a smart limit proposal is available to find a good setting taking the variation of the
current production into consideration.

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Fig. 4-6 Display of C setting, only one reference Fig. 4-7 Display of CC setting. Smart limits avail-
length to be set able for length classes from 2 – 12 me-
ters.

4.4.1 Yarn count deviations at start up (C) settings

The C-channel monitors the yarn count in the start-up phase after the splicing process. After the start-
up phase, the C-channel is not active anymore.

In the example of Fig. 4-8 the Cp (plus) setting is 10% and the Cm (minus) setting is -10%. The refer-
ence length (C) is 6 m.

Pressing key presents

TM
• The YARN BODY .

Clearing limit
A rea of actual yarn count.
Red dots = cut yarn faults

Fig. 4-8 Display of C setting, only one reference length to be set

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Scatter plot of yarn count monitoring at start-up / Practical example

Fig. 4-9 Yarn Ne 40, cotton 100%, combed, compact., Too short reference length (2m) adjustment and
too many cuts. It is recommended changing the reference length to 6m or 8m by keeping the
same + / - limits

Fig. 4-10 Yarn Ne 24, cotton 100%, carded. Fig. 4-11 Yarn Ne 24, cotton 100%, carded.
common setting, reference length Tight settings, reference length is 10 m.
is 10 m.

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4.4.2 Setting a smart clearing limit for yarn count monitoring (CC)

The CC-channel monitors the yarn count during the whole winding process. Depending on the setting,
long yarn faults with a small mass or diameter increase can be detected.

This new CC-channel is able to detect and remove count variations at different cut lengths between
2 m and 12 m these limits are fixed. The setting points are:
• 2 Set points: CCp +% at 2 m and 12 m
• 2 Set points CCm -% at 2 m and 12 m.

The lines between the set points represent the clearing limit.

Fig. 4-12 shows the YARN BODYTM and the actual clearing limit for CC. For a few seconds or minutes
the yarn runs with an automatically selected clearing curve (default value). After this period the opera-
tor can see the YARN BODYTM on the screen.

Pressing key presents

TM
• The YARN BODY .
• Scatter plot of the cut
• Number of cuts / 100 km.

Clearing limit

Red dots = cut yarn faults.

TM
= YARN BODY variation
TM
= YARN BODY

= Proposes the starting

point for the clearing limits based on
TM
the YARN BODY .

Fig. 4-12 Proposed setting is a starting point for optimization

By pressing Smart Limit function a proposed starting point for the CC settings will be selected. Ac-
cording to the need of the customer this proposal can be accepted or modified with the smart limit
function or manually.

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Fig. 4-13 Start with standard setting. Fig. 4-14 Only one step / Display of CC setting,
Press Smart Limit key smart limits available for length classes
from 2 – 12 meter

After pressing the Smart Limit key, a small window with the two appropriate keys to adapt and opti-
mize the smart limit for CC appears. The Smart Limit has been developed to propose a starting point
for the clearing limits by pressing one button. This proposal can be altered by up and down keys to
optimize the settings according to the individual quality requirements and productivity. It is recom-
mended to use the Smart Limit function after a minimum of 30 km of yarn has already been wound.

Of course all settings recommended by smart limit can also be altered manually.

As soon as the button at the smart limit window is pressed, the YARN BODYTM and scatter plot is dis-
played on the setting page.

=
The new setting point proposals

= Smart Limit 1, step less sen-

sitive.

= Smart Limit 1, step more

sensitive.

TM
= Show YARN BODY
and scatter plot

= confirm and activate opti-

mized clearing limit.

= cancel all modifications

Fig. 4-15 Proposed setting is a starting point for optimization

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C and CC faults are displayed together with all other yarn faults of the machine, a group or a winding
position.

Fig. 4-16 C and CC fault reports

Scatter plot of medium-term deviations / Practical example

Fig. 4-17 Frequent medium-term deviation of the count. Analysis of the spinning process required.

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Fig. 4-18 Yarn Ne 40, cotton 100%, carded. Fig. 4-19 Yarn Ne 32, cotton 100%, carded.
quite open setting already giving 0,9 + 0,2 High number of count deviations between 2
= 1,1 cuts per 100km and 12 m, 3,4 + 1,5 = 4,9 per 100 km.

Fig. 4-20 Yarn Ne 12, cotton 100%, carded. Fig. 4-21 Yarn Ne 16, cotton 100%, carded.
High number of count deviations within This example illustrates awide spread varia-
the range of 2 to 12 m, 8,3 + 2,6 = 10,9 tion (light green area)
per 100 km.

4.5 Calculation of yarn count deviations

The determination of the setting parameters for the yarn count deviation monitoring must be carried
out very carefully. Different aids are at disposal.
• Determination of count variations with the clearer installation
• Calculation of the count variations with formulas
• Determination of count variations with a diagram
• Determination of count variations with the USTER® Calculator

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4.5.1 Determination of count deviations with the clearer installation

As described before, the mean value of the yarn is determined from the single winding positions and
is detectable as the ADMV-value at the Control Clearing Unit. This means, this value presents the
100% - value of the yarn. This value can also be used for the calculation of deviations between bob-
bins. The ADMV takes factors like the material or the relative humidity already into account.

It is possible to calculate the count deviation in percent according to the following formula:

Formula 1:

Wrong yarn B( ADMV) − yarn A( ADMV)

Mass deviation( %) = ⋅ 100%
yarn A( ADMV)

ADMV = Yarn mean value / value which is generated by the sensor as an electrical signal when
inserting a yarn in the measuring slot.

Example 1: Article A is mixed up with a coarser yarn, article B (capacitive measurement)

• Article A: Ne 30 ADMV: 776

• Article B: Ne 20 ADMV: 1204,2

Wrong yarn B( ADMV) − yarn A( ADMV) 1204,2 − 776,0

Mass deviation( %) = ⋅ 100% = × 100 = 55,2%
yarn A( ADMV) 776,0

This means, that the difference between Ne 30 and Ne 20, measured with the capacitive sensor, re-
sults in a mass increase of 54,6%.

Example 2: Article A is mixed up with a coarser yarn, article B (optical measurement)

• Article A: Ne 30 ADMV: 4578,4

• Article B: Ne 20 ADMV: 5513,6

Wrong yarn B( ADMV) − yarn A( ADMV) 5513,6 − 4578,4

Diameter deviation( %) = ⋅ 100% = × 100 = 20,4%
yarn A( ADMV) 4578,4

This means, that the difference between Ne 30 and Ne 20, measured with the optical sensor, results
in a diameter increase of 20%.

The percentage differences are limits. They should only be used as a guideline for the C- and CC-
settings. Experience has shown that a certain tolerance must be taken into account. This means, the
selected settings should be lower than the calculated values.

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4.5.2 Calculation of the count deviations of wrong bobbins (capacitive measurement)

Count deviations between yarns of the same fiber material

For the iMH-C count deviations can be determined according to formula 1 below:

Formula 2:

Wrong yarn B( tex) − yarn A( tex)

Mass deviation( %) = ⋅ 100%
yarn A( tex)

Example 1: Article (yarn A) is mixed up with a finer yarn

Yarn A (33,3 tex) is mixed up with yarn B (25 tex)

( B − A) ( 25 − 33,3) − 8,33
Mass deviation( %) = ⋅ 100% = ⋅ 100% = = −25%
A 33,3 33,3

Example 2: Article (yarn A) is mixed up with a coarser yarn

Yarn A (25 tex) is mixed up with yarn B (33,3 tex)

( B − A) ( 33,3 − 25) 8,33

Mass deviation( %) = ⋅ 100% = ⋅ 100% = = +33%
A 25 25

Count deviations between yarns of different fiber material

If count deviations between yarns of different fiber material in blended yarns should be monitored, the
deviations can be calculated with formula 2 below. The different material factors have to be taken into
account.

Formula 3:

value of yarn B −( yarn A × factor)

Mass deviation( %) = ⋅ 100 %
A × factor

Yarn material Factors Relative humidity

Cotton, wool, viscose 0,86 80%
0,77 65%
0,69 50%
Acetate, Acrylic, Polyamide 0,62 65%
Polypropylen, Polyethylene 0,56 65%
Polyester 0,50 65%
Polyvinylchloride 0,45 65%

Table 4-1 Factors of the yarn material

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Example 3: Article A made out of Polyester is mixed up with article B made out of cotton
Yarn A: 20 tex: 20 x factor 0,5 = 10
Yarn B: 20 tex: 20 x factor 0,77 = 15,4
15,4 − 10
Mass deviation = ⋅ 100% = + 54%
10

Example 4: Article A made out of cotton is mixed up with article B made out of Polyamide
Yarn A: 27, 8 tex: 27,8 x factor 0,77 = 21,4
Yarn B: 23,8 tex: 23,8 x factor 0,62 = 14,8
14,8 − 21,4
Mass deviation( %) = ⋅ 100% = − 31%
21,4

If the wrong bobbins deviate from the nominal yarn with respect to yarn material and yarn count, then
the mass deviation has to be calculated according to formula 3:

E
xample 5: Article A made out of cotton (20 tex) is mixed up with blended yarn B PES/CO
67/33% (19,2 tex)

Yarn A: 20 tex: 20 x factor 0,77 = 15,4

Yarn B: 19,2 tex: (B x factor PE x %-share) + (B x factor CO x %-share) =
(19,2 x 0,5 x 0,67) + (19,2 x 0,77 x 0,33) = 11,3
11,3 − 15,4
Mass deviation( %) = ⋅ 100% = − 27%
15,4

In order to compensate the variation of the yarn count, the channels C and CC should be set to an
about 5% more sensitive value than the calculated value.

4.5.3 Calculation of count variations of wrong bobbins – optical measurement

As the iMH-O measures the yarn diameter, the count deviations must be converted in differences of
the yarn count. This can be done quite easily with the aid of the USTER® Calculator (see section
4.5.5).
• Determination of the mass deviation according to the following examples 1 and 2.
• Conversion of the mass deviation to diameter deviations with the help of the USTER® Calculator.

Example 1: Article A (33,3 tex) is mixed up with bobbins B (25 tex)

B−A −8,33
Mass deviation( %) = ⋅ 100% = ⋅ 100% = − 25%
A 33,3
-25% mass deviation  -13% diameter deviation

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Example 2: Article A (25 tex) is mixed up with bobbins B (33,3 tex)

B−A +8,33
Mass deviation( %) = ⋅ 100% = ⋅ 100% = + 33%
A 25
+33% mass deviation  +16% diameter deviation

It has to be taken into account that with the optical monitoring of wrong bobbins, the diameter devia-
tions are percentage-wise smaller than mass deviations.

In order to compensate the variation of the yarn count, the channels C and CC should also be set
about 5% more sensitive than the calculated values.

4.5.4 Calculation of count variation of wrong bobbins with a diagram

The following diagram can only be used for the calculation of count variations when the capacitive
measuring head is used.

% -50 -45 -40 -35 -30 -25 -20 -15 -10 -5

+5
130 B Nm/Nec +10

120 +15
+20
+25
110 +30

100
1 +35
+40
+45
+50
90

80 %

70

60

50

40

30

2
20

10
A Nm/Nec
10 20 30 40 50 60 70 80 90 100 110 120 130 140

Fig. 4-22 Determination of the mass deviation of yarns made out of the same material, but with a different
count

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Fig. 4-22 shows two examples for the calculation of mixed-up bobbins:
Example 1: article A, Ne 68 is mixed with yarn B, Ne 80 → deviation = -15%
Example 2: article A, Ne 50 is mixed with yarn B, Ne 40 → deviation = +25%

→ When this calculation is carried out in tex, the values A and B must be reversed.

4.5.5 Relationship between the mass and diameter deviation with the USTER® Calculator

In this section, only the relationship between the mass and diameter deviations will be explained,
which can be calculated with the aid of the USTER® Calculator. Scales ± and ″ of the calculator serve
for this purpose.

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Fig. 4-23 Conversion of mass and diameter deviations with the USTER Calculator
(6 = diameter scale, 7 = mass scale)

Depending on the measuring method and the unit which is used, the sliding tongue must be adjusted.

Example from Fig. 4-23: A mass deviation of 50% (7) corresponds to a diameter increase of only
about 22% (7).

Determination of the yarn count deviation with the USTER® Calculator

For the setting of the C- and the CC-channel, the value, which a wrong yarn must deviate in order to
be recognized, must be entered in percent.

Example:
1. First, the correct yarn count must be set with the vertical line of the Calculator. In case of Fig.
4-24, it is Nm 20 and 50 tex, respectively.

2. Furthermore, depending on the measuring method (capacitive or optical) the sliding tongue of the
Calculator must be moved so that the tongue for the spun yarn is on the "0" mark.

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Fig. 4-24 Setting of the USTER Calculator (1)

3. If a wrong yarn with the count Nm 18,5 (54 tex) should be detected, the sliding tongue must be set
on this count (see Fig. 4-25).

4. Then, in the middle of the Calculator (area marked red), the corresponding deviation in percent
can be read on the scale. In this case, Fig. 4-25, for the optical sensor it is 4%, for the capacitive
sensor it is 8%. The same procedure must be carried out for negative deviations.

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Fig. 4-25 Settings of the USTER Calculator (2)

4.6 Example for the setting of the C-channel

For the choice of the right setting of the C- and CC-channel, the scatter plot serves as a helpful tool.
The scatter plot shows the unevenness of a yarn, even for longer yarn pieces, very well.

For the correct setting of the channels it is necessary to know which faults were defined as not tolera-
ble by customers. It is also necessary to know the possibilities of the winding machine regarding the
setting of the suction length.

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From all this information, the settings for the clearer can be derived. An example for a correct setting
is explained in the following:

A spinning mill produces three different cotton yarns: Ne 20, Ne 30 and Ne 40. It is possible with a
normal unevenness of yarns to distinguish mixed up bobbins of these 3 yarn counts.

The setting of outlier or mixed-up bobbins is:

• iMH-C Cp: +24%

Cm: -20%
Reference length: min. 2 m or adjusted to the winding machine type

• iMH-O Cp: +12%

Cm: -10%
Reference length: min. 2 m or adjusted to the winding machine type

Due to the normal unevenness of a cotton yarn, it can be predicted that a more sensitive setting of
Cp/Cm can lead to unjustified cuts. It can also be said that the detection of counts anywhere between
Ne 20, Ne 30 and Ne 40 (e.g. Ne 24 out of a Ne 20) cannot be guaranteed anymore.

Rule of thumb for iMH-C:

The setting for the C-channel with a reference length of 2 to 4 m should not be set more sensitive
than the CVm of the yarn.

Rule of thumb for iMH-O:

The setting for the C-channel with a reference length of 2 to 4 m should not be set more sensitive
than 70% of the CVm of the yarn.

4.7 The effect of count deviations on the fabric appearance

4.7.1 Mixing two different yarn counts

Bobbins with different yarn counts can be accidentally mixed up during yarn production, or there can
be count deviations within a cone. These count deviations can cause long stripes in the fabrics which
are visible to the naked eye.

In this example, we have knitted ten rows of reference yarn (Ne 30, 20 tex) and ten rows of a finer
yarn (Ne 34, 17,5 tex) spun from the rovings produced by using the same cotton blend, using the ring
spinning method. We can observe horizontal dark and light colored lines in both the greige (Fig. 4-26
and Fig. 4-27) and the dyed samples (Fig. 4-28 and Fig. 4-29). These horizontal lines are the result of
yarn count differences. There is also a difference between the diameter 2DØ values of these two
yarns (Table 4-2).

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Yarn Twist Twist CVm Thin - Thick Neps H 2DØ CV2D D (abs)
3
Count 1/m direc- % 50% +50% +200% mm (8mm) g/cm
(Ne) tion
Reference 30 830 Z 12.7 0.5 34.5 66 4.6 0.22 9.6 0.5
USP13 61 29 71 73 22 18
Wrong count 34 883 Z 13.5 6.0 52.5 90 4.5 0.20 10.3 0.5
USP13 77 >95 82 77 25 27

Table 4-2 Yarn quality results

USP13 = USTER® STATISTICS 2013

2DØ = Optically measured diameter with the USTER® TESTER 5 / Measurement of the yarn di-
ameter with 2 light beams of 90 degrees
D = Density measured with the USTER® TESTER 5

Fig. 4-26 Reference fabric (greige) Fig. 4-27 Defective fabric (mix-up of reference
yarn with a finer count yarn) (greige)

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Fig. 4-28 Reference fabric Fig. 4-29 Defective fabric (mix-up of reference
yarn with a finer count yarn)

In a similar trial, we have used ten rows of a coarser yarn (Ne 26, 22,5 tex) and ten rows of reference
yarn (Ne 30, 20 tex) and produced knitted fabric samples. Again in both the greige and the dyed sam-
ples, we can observe horizontal dark and light colored lines. As mentioned previously, these horizon-
tal lines are the result of yarn count differences. There is also a difference between 2D-diameter val-
ues of these two yarns (Table 4-3). The pictures are not shown here, as the appearance of the previ-
ous sample (with finer yarn) and this one are very similar.

Yarn Twist Twist CVm Thin Thick Neps H 2DØ CV2D D (abs)
3
Count 1/m direction % -50% +50% +200% mm (8mm) g/cm
(Ne)
Reference 30 830 Z 12.7 0.5 34.5 66 4.6 0.22 9.6 0.5
USP13 61 29 71 73 22 18
Wrong count 26 770 Z 12.0 0.0 22.0 32.5 4.9 0.24 9.5 0.5
USP13 50 <5 60 54 32 27

Table 4-3 Yarn quality results

In another example, we have knitted 10 rows of reference yarn (Ne 36, 16,5 tex) and 10 rows of a
coarser yarn (Ne 30, 20 tex) spun from the rovings produced by using the same cotton blend.

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4 Count variations

Then the knitted fabrics were dyed and T-shirt samples were produced. In the fabric and the T-shirt
sample, we can observe horizontal dark and light colored lines (Fig. 4-30 to Fig. 4-33). These horizon-
tal lines are the result of yarn count difference (Table 4-4). Both yarns have the same evenness, but
as a result of different counts the diameter is different.

Yarn CVm Thin Thick Neps H 2DØ CV2D D (abs)

3
Count % -50% +50% +200% mm (8mm) g/cm
(Ne)
Reference 36 12.6 0.6 33.1 71.7 5.2 0.20 9.6 0.5
USP13 48 19 61 65 76 40
Wrong count 30 12.6 0.90 33.8 52.3 5.6 0.23 9.8 0.5
USP13 50 32 62 52 90 55

Table 4-4 Yarn quality results

Fig. 4-30 Reference T-shirt Fig. 4-31 Defective T-shirt (mix-up of reference
yarn with a coarser count yarn). Stripes
in the direction of the arrow
(see also Fig. 4-33).

Fig. 4-32 Reference fabric Fig. 4-33 Defective fabric (mix-up of reference
yarn with a coarser count yarn)

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 Count variations 4

4.7.2 Reasons and measures to minimize count variations

In Table 4-5 and Table 4-6, the origin of faults related to long-term mass variations is given. Possible
reasons and preventive measures to avoid such faults are explained and various USTER® tools for
improvement are presented.

Yarn Count Variation

Origin of Faults Possible Reasons and Preventive Actions

Drawing frame Use autoleveller on finisher drawframe

Roving frame Weight variation of rovings
Check roving trumpet hole diameter and cleanliness at the trumpet
input
Use different color of roving tubes to avoid roving count mix-ups
Ring spinning frame Improper roller weightings
Spinning creel alignments
Dragging bobbin holders
Blocked spinning trumpet
False draft in ring spinning machine creel
Instruction and training of operators
Use of different colors of spinning tubes to avoid count mix-ups

Table 4-5 Preventive measures and tools for the management of long-term mass variations

®
Yarn Count Variation / USTER Tools for Improvement
Tools Improvement
® ®
USTER Testing off-line Constant quality control of sliver and yarn quality with the USTER
TESTER
®
USTER Testing on-line Adjustment of autolevelling system
®
USTER QUANTUM CLEARER Separation of outlier bobbins with quality data software of the yarn
clearer
Correct settings of C and CC channel
Use C and CC alarm settings for eliminating wrong spinning bobbins
®
USTER EXPERT SYSTEMS Monitor long-term variation of cut ratio and yarn quality

Table 4-6 Preventive measures and tools for the management of long-term mass variations

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4 Count variations

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