Operators have to be everywhere at the same time, checking, repairing, keeping machines running continuously, no matter in any weaving mill, anywhere in the world. Operators must work very fast and see as well as an eagle and with the know-how of an engineer and a service technician for different types of weaving machines. As operators with these skills are very rare, it is true that most of them are stressed.
This type of stress can be a risk to the profitability of weavers. The faults could be repeated, appearing over and over again, for as long as it takes to identify the fault and resolve the problem. Long-lasting faults can also stem from dirty parts or from missing or inadequate maintenance. It can spoil a lot of good fabrics. Q-Bar 2 is the solution to detect them, working with different types of weaving machines (except waterjet and jacquard), Uster said in a press release.
Uster Q-Bar 2 has its inspection position in the tissue formation area, which allows it to react quickly when a defect appears and to avoid long lasting or repeated defects. Alarms and shutdown signals alert the operator to correct problems immediately. This early detection reduces second grade and loss of material. Q-Bar 2 also monitors critical machine units in the training area. If there is a problem here, the system makes it easy to identify and eliminate it, thereby avoiding further defects and maximizing fabric yield again.
Smart weaving machines flag issues to the operator, but Q-Bar 2 sees what weaving machines can’t. For example, the operator constantly solicited repairs a broken warp thread, picking up the thread and pulling it in the comb position; loom sensors receive the signal that the missing yarn is now available and accelerate to full speed within milliseconds. Immediately, an alert starts at Q-Bar 2, with a red light indicating the location of the problem. Without the Uster training monitoring system, the fault was not detected because the operator had already moved on to solving the next problem on another machine, according to Uster.
Intricate patterns, fine threads, and inexperience can all lead to poorly stretched warp threads, flaws that are difficult to recognize with the naked eye. Without an automatic solution in place, the problem of bad prints usually goes unnoticed until it is woven into the fabric a few yards in length. The best way to avoid poor quality is to simply not do it. A zero defect standard is what many weavers want to achieve. Q-Bar 2 is the way to go. Weaving defects can have various causes, which is why Uster Q-Bar 2 provides different algorithms to identify specific defects and their causes. With this knowledge, it is possible to avoid defects during the actual weaving process.
Uster Q-Bar 2 monitors tissue already at the critical stage of tissue formation with automatic in-line inspection. Identifying the issues here brings huge benefits and allows weavers to offer consistent quality and remain competitive in the market.
Fibre2Fashion Information Office (GK)
Uster launched the Q-Bar 2 training monitoring system. It is like an additional operator dedicated to a single weaving machine. Uster provides quality management solutions from fiber to fabric. The Swiss-based company offers high-tech instruments, systems and services for quality control, certification and optimization in the textile industry.