清纱新时代

A new era in yarn clearing

客户的反馈彰显了新一代USTER®QUANTUM 3带给客户的影响及效益

Customer feedback underlines theimpact and benefits of the new-generation
USTER® QUANTUM 3

2013年10月16日瑞士乌斯特——USTER®QUANTUM 3 清纱器发布于2012年9月，在操作简单、应用范围以及为客户带来的效益方面取得了巨大的飞跃。新一代的系统将清纱带入了一个全新的时代，系统会自动推荐一个最佳的切纱设定，并且纱体概念的应用提供了快速的质量参考。乌斯特在全球范围内发布了这一款清纱器，并随即基于纺厂的实际应用状况仔细回顾了这些客户的经验。

Uster, Switzerland, October 16, 2013 –The launch in September 2010 of the USTER®QUANTUM 3 yarn clearer was a massiveleap forward in range of capability, ease of use and customer benefits. Thisnew-generation system propelled yarn clearing into a new era, with itscapability to suggest optimum cut settings automatically and its use of theYARN BODY concept to provide an instant quality reference. USTER launched theclearers globally and subsequently undertook a detailed review of customerexperiences, based on practical use under mill conditions.

创新是USTER®QUANTUM 3 研发的核心。首次以来，一款全新的清纱器超越了人们的普遍期望——推荐清纱设限以及预测切次水平。异物清除性能得到了极大的提升，能识别有色异物并进行选择性地清除那些可能影响织物质量的纱疵。丙纶检测时也涵盖支数变异以及周期性纱疵检测功能。简单、安全的清纱是目标，根本目标还是帮助纺厂提升质量及产能。

Innovations were at the core of the USTER? QUANTUM 3 development. For the first time, a yarn clearer went beyond normal expectations - with its ability to propose clearing limits and predict cut levels. Foreign matter clearing was dramatically upgraded, with the ability to see colored defects and remove selectively the faults likely to affect fabric quality. Polypropylene detection capability was also extended to cover count variation and periodic faults. Simple, errorfree clearing was the aim, with the ultimate goal of helping spinners raise quality and productivity.

来自全球的最初反响非常好：客户对产品留下了深刻印象。尽管产品问世前的测试确立了对该产品的信心，但是乌斯特还是决定用实际证据来支持这一点，通过大范围的工厂访问，从客户那里拿到了第一手关于使用环境、生产应用和质量需求的反馈。新型清纱器帮助客户实现了所需价值吗？反馈表明确实实现了，并且一种全新的清纱方法也随之诞生了。

Initial reactions around the world were positive: customers were said to be quite impressed. Prelaunch testing had confirmed initial confidence in the product, but USTER determined to support this with practical evidence, visiting spinning mills to get firsthand feedback from customers across a wide range of mill environments, applications and quality requirements. Was the new clearer delivering the benefits customers needed? Feedback suggested it was, and that a new approach to yarn clearing was born.

铁的事实会滋生惊喜

Hardfacts can spring surprises

如今——首次安装后33个月，近50万个USTER®QUANTUM 3 销售出去了——这一数字连乌斯特专家都感到惊喜。这些清纱器安装在全球10000多台自动络筒机上，如中国、印度、土耳其、巴基斯坦、孟加拉、印度尼西亚、越南、韩国、意大利、埃及等纺织热点地区，还有诸如西班牙、阿根廷、危地马拉、坦桑尼亚、俄罗斯以及乌兹别克斯坦等小规模纺织国家。使用工厂包括从自络机的初次使用者到有着很高质量要求的经验丰富的使用者。使用环境温度横跨10到53摄氏度，相对湿度从20%到80%。超过300种纤维产品，包括传统的棉、涤纶、粘胶及其混纺，还有诸如亚麻、莫代尔、天丝、蚕丝、羊绒、弹力氨纶丝以及非弹力丝包芯纱等类型。这些应用事实证明了USTER®QUANTUM 3 足以胜任各种不同的生产环境、应用以及期望。但是客户从哪些方面来提升质量和产能呢？

Today 33month after the first installations, and with half a million USTER®QUANTUM 3 clearers sold the facts havesurprised even USTER's own experts. The clearers are now installed in over10.000 automatic winders around the world, in textile hotspots like China,India, Turkey, Pakistan, Bangladesh, Indonesia, Vietnam, Korea, Italy andEgypt, as well as in lessobvious markets such as Spain, Argentina, Guatemala,Tanzania, Russia and Uzbekistan. Mills range from firsttime entrants inautomatic winding to sophisticated users with very high quality demands. Theyspan environmental conditions from 10 degrees Celsius to 53 degree Celsius,from 20 percent relative humidity to 80 percent. Over 300 fiber types wereprocessed, including traditional cotton, polyester, viscose and their blends aswell as flax, modal, Tencel, silk, cashmere, elastane and nonelastane coretypes. These facts prove USTER®QUANTUM3 is flexible enough to handle varying conditions, applications andexpectations. But what are the customer benefits in terms of quality andproductivity?

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最佳的清纱设限：简单、快速

Optimalclearing limits: quickly and simply

客户们都很欣赏纱体这一概念，它使得系统的应用更加简单。并且达到最佳的清纱界限非常快速、简单——之前一直处于争论之中，如今客户都接受纱体这一概念并作为清纱的一个必要元素。

Customerswere united in their appreciation of the YARN BODY concept, which made thesystem much easier to use. It was easy and fast to arrive at an optimalclearing limita factor which was always a matter for debate with users nowwelcoming the YARN BODY as an essential element in yarn clearing.

许多客户也反馈到质量投诉的减少，特别是针对条干更均匀的纱线，如紧密纺纱。之前，清纱界限不能清除这些纱线的异常，因为纺厂经常遵循“分级清纱”。纱体一览图使得这些纱疵更为直观明显，而纺厂也能相应地调整设限。如下图USTER®CLASSIMAT 5上的示例（图1和图2）清晰显示了这些反馈的影响。纱线是紧密纺纱线，但是清纱使用的是传统的分级清纱导致一些纱线异常仍然存在，图中显示的深绿色的小三角——USTER®CLASSIMAT 5的纱线分级系统的一项特殊功能。

Many customers also reported the elimination ofquality complaints, especially with more even yarns such as compact yarns.Previously, clearing limits had been unable to eliminate outliers for theseyarns, as spinning mills often followed the 'class clearing' approach. The YARNBODY view made these faults much more obvious, and mills were able to adapt thelimits accordingly. The example below (fig. 1 and 2) from the USTER®CLASSIMAT 5 clearly shows the impactof this feedback. The yarn is a compact yarn, but clearing using traditionalclasses left some remaining outliers in the yarn, indicated by the dark greentriangles – a special feature of the USTER®CLASSIMAT 5 yarn classification system.

图一_紧密纺纱，使用传统分级清纱后仍存在异常（深绿色三角形）

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图二_普梳纱，清纱极限切入纱体（利用传统的分级清纱）
 

由于纱体一览图的出现，纺厂能在无需大幅增加切次的前提下清除异常。同样还有很多例子说明纺厂所设置的清纱界限范围太小。多亏了纱体的可视化，纺厂才能纠正这种设置并能够减少浪费、提升产能，同时能创造更高的利润。

As a consequence of the YARN BODY view, spinners hadmoved closer to eliminating outliers without increasing the cuts significantlyin such cases. There were also many examples of spinning mills definingclearing limits that were too close. Thanks to the YARN BODY visualization theycould correct them resulting in saving waste and in increasing productivity,both leading to higher profits.

识别生产过程中的问题

Identifyingprocess disturbances

据一些纺厂经理报告，他们已经将这些变化应用到日常工作中了。因此他们能够在工厂巡查的时候随机地查看纱体。“纱体是加工过程及原料状况的显示器——如果形状上有什么异常，更大的浅绿色区域就会产生，我们就能讨论如何去改善。”巴基斯坦的一名客户如此说道。许多有着高品质需求的纺厂也进行了这些尝试来监察纱体的改变，利用散点图来发现生产过程的问题并提出改善意见。例如（图3及图4），一家印度的纺厂注意到在8-32厘米区域有着许多纱疵。这一现象触发了相关的调研，并最终实现了最佳的梳棉机速度设定以及切次、织物质量的大幅提升。

Some millmanagers also reported they had implemented changes to their routines, so thatthey were now checking the YARN BODY randomly during patrols in the mill."The YARN BODY is an indicator of process and raw material situation ifsomething was unusual in the shape or a larger light green area triggered, wecould discuss some improvements," explains a customer in Pakistan. Anumber of mills with higher quality demands also carried out trials to monitorthe changes in the YARN BODY, using scatter plots to find process issues andsuggest improvements. For example (fig. 3 and 4), a mill from India noticed anunusual number of events in the 8 cm to 32 cm area. This triggered investigationsleading to optimum carding speed settings and considerable improvement in cutsand fabric quality.

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图三_纱体应用之前，在8-32厘米区域的纱疵
 

图四_纱体应用之后，调整梳棉机速度之后的提升改善
 

此例以及其他许多例子，都印证了纱体作为一个能帮助迅速认识并理解纱线条干及变异的优良参量的价值。总的原则为：纱体越窄，织物质量越好。这一比较工具已被应用到USTER®CLASSIMAT 5。

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This, and many other examples, underlined the value ofthe YARN BODY as a good parameter to gain an understanding of the yarn evennessand its variations, at a glance. The general rule is: the narrower the YARNBODY, the better the fabric quality. A comparison tool is now incorporated intothe USTER®CLASSIMAT 5.

同时也有一些纺厂报告到在管理这一创新的多功能系统过程中的遇到的初期困难。大体的反应是决心应用后变得更有效率，即使这意味着在流程上得有所改变。“我听许多客户反映他们如何重视易用性以及清纱设限建议”Sivakumar Narayanan，乌斯特公司清纱器产品经理如是说道。“事实上，一些客户告诉我们，他们已经不记得在应用USTER®QUANTUM 3 纱体概念之前，他们是如何设定清纱曲线的了”。

While some mills reported initial difficulties inadapting managing the innovative multiple systems, the general reaction was adetermination to improve and become more effective, even if this meant changesin procedures. “I have heard from many customers how much they value the easyuse and the clearing limit proposals”, says Sivakumar Narayanan, ProductManager of Yarn Clearing, within Uster Technologies Ltd. “In fact, somecustomers told us they could hardly remember how they operated their yarnclearing installations before the YARN BODY concept with USTER®QUANTUM 3.”