This document discusses online quality monitoring systems used in modern spinning mills. It describes several key online monitoring systems such as cotton contamination sorters, autolevellers at carding and drawing stages, and quality monitoring systems at ring frames and winding that provide data on production efficiency, defects, machine performance, and more. It emphasizes the importance of properly processing online data, correlating it with offline test results, and using the information systematically to improve productivity and quality.

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2. SPINCLINIC SpinningKnowtedgeENHANCER
On-lineQualityMonitoringSystems
inSpinning
Mr,SunilKumarSharma,Manager- QAD,PPC& CustomerCare,LoknayakfayprakashNarayanShetkariSahakariSoot
GirniLtd.,MH
Abstract
Rapidchangesin technologyalsochang-
es every aspect of life. Technological
changesin industriesnot only changed
productiviry& qualirybutalsochanged
work culturetoo. Technologicalup-
gradationof spinningmachineriesalso
makeseasyoperation,higherproduc-
tivity, user friendly maintenanceand
moreinformativeproductionupdateat
any moment,online qualitymonitor-
ingsystemsarepartoftechnologicalup-
gradationof spinningmachineries.All
thenewgenerationspinningmachiner-
iesequippedwith somespecialfeatures
of "0n-lineQualityMonitoring"devises.
Mostof thesedevicesareintegralpart
of machinery,howeversomesystems
availableasoptionalattachmentonextra
cost.Informationprovidedbytheon-line
systemsmayhelpful,if it isproperlypro-
cessedandutilizedinsystematicmanner.
Thepurposeof this articleis to elabo-
ratevariousonlinemonitoringsystems
availablein modernspinningmills,sys-
tematicprocessapproachand utiliza-
tionofinformationobtainedforeffective
monitoring,It'scorrelationwith off-line
Jaboratorytestresultsanduseofthisin-
formationforcustomerandothersstack
holder'sreferenceswithfullauthenticity.
Introduction
Proper& systematicutilizationof "0n-
line Quality MonitoringSystems"in
spinningmillsmayimproveproductivity
& qualitylevelsignificantly.
Mostofthenewgenerationmachineries
workson electronicallycomputerbase
systems,thisprovidemore&moreonline
informationfor qualiry& productivity.
Informationobtainedfrom on-linesys-
temsissignificantlydifferwithoff-lineor
78 | SpinningTextilesI Nov-Dec2014
laboratorytestresults.Hencefollowing
guidelineshouldfollowforprocessingof
on-lineinformationl
1. 0nline informationmaybemore
accuratefor longtermreportsas
comparetoshorttermreport.
2. A co-relationfactor shouldbe
derivedbycomparingtheonline
dataw.xt.off-lineor laboratory
testby comparingsignificanttest
samples.
3, Itshouldbeco-relatedperiodically
withofflineorlaboratorytest.
4. Online sensorsshould check
regularlyfor its accuracyand
properfunctioning.If requireit
shouldbecalibrated,
5, Atmosphericcondition to be
monitoreverytime,whenacquire
theon-linedata.
On-line Monitoring Systems in
Spinning
Following"0n"lineMonitoringSystems"
arecommonlyusedinspinningmillsl
CottonContaminationSorter(CCS)
Cottoncontaminationsortersare op-
tionalonlinequalitymonitoringdevices,
whichdetect& removetheforeignmat-
ter fromcotton.CCSprovidesinforma-
tionthathowmanyforeignmatterpoints
detectedand removedby the systems
andrecordedintosystemPCas"Eiection
/ Minutes"or"Ejection/Hrsl'
Theseinformationmayobtainashours
wise,daywiseor rnonthwise,basedon
programmingavailablewith systemPC,
CCSisveryimportanton-linemonitoring
devices for contamination removal.
Accuracyof CCSmayobserveby putting
colourpaperpiecesof onesq,cm.each
into b)Dw rcDm pjpe )jne )Dst befDre
CCSand see how much out of them
e.iectedthroughCCS.Thisshowsthe CCS
efficiencyfor differentcolours.Cleaning
of CCSglasses,camerasandlight source
and cotton path affectthe performance
of CCSsignificantly,henceit should be
maintainedproperly and 0perational
instructionsshouldbefollowedstrictly.
On-lineMonitoringSystemsat Carding
Stage
Ali the newgenerationcardingmachin-
eries equippedwith short term as well
as long term autolevellerfunction.Au-
tolevellermonitorthe uniformityof feed
material as well as deliveredmaterial
and correctedwheneverdeviatedfrom
describedvalue,
Productionmonitoringsensorplacedon
deliveryroll monitorsthe lengthof out-
put sliverand calculatethe production
& machineefficiency,Followingparam-
eters may obtain and monitored with
^^-li-^ i*r^-*^+^-.,.
! 4 , u u , 5 , , , , u , , , , a r u ' ] .
. o/oFeedvariation
. Cvo/owithdifferentcutlength
. A%deviationoractualsliverweight
. No.ofBreaks& itscauses
RieterQ-packalsoprovidesfollowing
additionalqualitydata:
. on-linemassspectrogram
. Slub/Thickplacesper km in sliver
w.r.t.differentdiameteri.e.+ 15%to
457ointhestepof5%diameter

3. r ' a
f
i ' . * t , i *
Thisinformationmayberecordedshift
wiseordaywiseformonitoring.
On-linesystemsfor Br. DF'sUnilap
/ Lap Formers& Combers& SPeed
Frames
Normallythesemachinesareequipped
with productionmonitoringsensors
only,henceonlyfollowinginformation
maybeutilized:
. Machine& ProductionEfficiency
. Machinedowntimes
. No.ofbreaksoccurred
. Causesofbreaks
On-lineQualityMonitoringatRSBDF's
Aftercarding,qualitymonitoringdevises
placedat RSBDFsonly,whereagain
autolevelleris functioningfor better
evennessandcontrolof lineardensity
0i sliven0n-linequalitymonitoring
systemsat RSBDF'sprovidesfollowing
informationi
. %Feedvariation
. cv%withdifferentcutlength
. Ao/odeviationoractualsliverweight
. On'linemassspectrogram
. Slub/ Thickplacesperkilometerin
sliverwr,t,differentdiameter
Accordingtoqualityrequirementswarn'
ing & stoplimit mayset for different
qualityparameters,Machinewarning
lightsblinks,whenanyqualityparameter
goesbeyondthesetwarninglimits,while
machinestopimmediatelyif anyquality
parameterscrossesthe describedstop
limit,
0n-line MonitoringSYstemat Ring
Frame
On-linemonitoringsystemsavailablefor
Ringfuamesare optionalattachments
only.Thisis veryuniqueandimportant
systemfor measurement& monitoring
ofringframeperformance.Systemm0ni'
torsquality& productiviryofringframes
continuouslyroundthe clock.Thissys-
temworksinacombinationoftwodiffer-
entsensorslocatedatdifferentpositions
atringframesformonitoringthevarious
functions.TheseareSinglespindlemoni-
toring[SSM)& productionmonitoring
(PM).A travellingsensorperformsthe
Singlespindlemonitoringfunctionwhile
B0I SpinningTextilesLNov'Dec2014
productionmonitoringsensorplacedon
thefrontdeliveryrollofmachine.
i. Start up Breaks(STU):Breaks
recordedat the start of the
machineafter doffingwithin a
preselectedtime.
ii. Normal Breaks(EB): Breaks
recordedafterstartuptill doffis
OVEI,
iii. Other Breaks(PRTI: Breaks
otherthanSTU& EB,normally
idlespindles,
100%Spinning
Setting of QMSat RSBDF's
RSBDF'sare very sensitivemachinefor quality aspects.Hencethe settingof
on-linequalityparametersis a very preciousmattexIt shouldbevery perfect&
accurate.Warninglimit & stoplimit ofsystemsshouldbetreatedas
'ActionLimit"
& "ControlLimit".
WarningLimit =ActionLimit
StopLimit = ControlLimit
Forexampleif in a spinningmill allowableFin DFsliverhanp1;s1115+/- 2 0 %
andbeyondthis limit beingtreatedas"Non-confirmproduct",then
. Warninglimit shouldbeseton+/- 1.50/0,wherewaminglightswill blinkfor A
%odeviation.
. Stoplimit to be setat +/- 2.0%0,whereno productionwill allowbeyondthis
limit andmachinewill stopimmediately.
. Similarlywarning & stop limits may be decidedfor CV%, Thick places&
Spectrogram,
. MomentarystopsPositions(MsP):
Momentarystopspositionsat any
instance,
TravellingSensor ' Idlespindles:Spindleswhichdonot
One travelling sensor moves ftom produceanythingfor a "setoftime"
oneendto anotherendof dng fuame arelistedas idlespindlesUsually
and monitorthe ring travellermotion spindlesstoppedfor morethan30
andsendtheinformationto CPU.CPU Minutesareconsiderasidlespindles
processedthe informationreceived ' RogueSpindles:Enablestheuserto
with travelingsensorandcalculatethe detectspindleswhichendbreaksrate
followingparameters: liessignificantlyabovethe machine
average
. Ends Downi Ends down at any ' WorstSpinningPositions:Thisre'
instanceobtainthroughsystemsPC portshowsamaximumof10spindles
. EndBreaksRate:Nomotionofring withspindlenumber/machinenum-
travellerrecordedasendbreaksof berwithhighernumberofbreaks'
particularspindleposition lt may ' Actual Spindle SpeedrRotational
obtainEndbreaksper1000spindles speedof each& everytravelleris
Perhoursforaparticularringframe measuredby the travellingsensor
Endbreakagesclassifiedintothree andthemeanRPMof the machine
wDesi storedinsystem
. TPM/ TPhTwistpermeter/ twist
perlnch,
. Slip Spindles7or The individual
travellerspeediscomparedwiththe
"MeanRPM"ofthemachine.Aspindle
will berecordedasa slipspindle,if
it'stravellerspeedobservedIessthan
thelimitset(i.e.3- 5%)for more
thanthenumberoftimesset.
StationarySingleSpindleMonitoring
System
. End Mending Time (EM)r Mean Now dayssomemachinerymanufac-
durationof normalend breaksin turesalsodevelopedinbuiltstationary
minutes,This indicatesoperator singlespindlemonitoringsensors,which
efficiencv placedateachspindles.

4. SPII'iCLINIC
Production Monitoring Sensor
Productionmonitoringsensorattached
at deliveryroll of ring frames,monitor
frontrollspeed& afterprocessedthrough
CPUfollowingparameterscalculated:
. Front Roll Speed:Actual front roll
deliveryspeedin RPM.
. DeliverySpeeds:Yarndeliveryspeed
in meters per minutes calculated
fromfrontrollspeed,
. Total RingFrame production: Total
ringframeproductionatanyinstance
and for a definedshifldurarionin
Kg./Hrsor Kgs.
. cms per Spindle per Shift; Shift
wiseGPSSf0rcount-wise,group-wise
& ring ftamewise.
. Total Down Times (STM): Total
down time minutes since the
beginningoftheshift.
. Efficiency:AEF0/oi.e.Actualefficien-
cy, PEF0/oi.e.productionefficiency,
NEF o/o Now efficiencymay get
throughsystem,
. No. of Doffs in a Shift: TotalNo.of
doffssincethe beginningof the shift.
This report helpsto monitor doffing
loadofring framedoffers,
. Doffing Time (DFM): Total doffing
time in minutessincethe beginning
ofrheshift.Thisreportheipstomoni-
tor ringframedoffingteamefficiency.
TypeofReports
Varioustypesof reportsmaygenerate
throughsystemforanalysis&monitonng
purposes.Theseareasfollows:
InstantaneousValueReport
Showsthestatusofthemachine[sJatthe
momentof call-up(i,e.instantaneousJ.
Noperiodisapplicablef0rthisreporr.
ShiftReports:
Automaticshiftreportmayobtainedat
theendofshiftwithdefinedparameters.
StoppageReports
overallanalysisbasedon stop causes
possiblewithorwith0utreferencetome
machinenumber.Reportsmayobtainin
form of Stopsummarystophistory&
stopdiagram.
LongTermReports
Longtermreportsfor a fix interualr.e.
82 | SpinningTextilesI Nov-Dec2014
on weeklybasisor monthlybasismay
obtained.
Article Wise
In this report machinesprocessingthe
samec0unt/ materialarelistedtogethen
Operator / SupervisorSectionWise
This report providedan overyiewof the
machinedataas per work assignment
allottedto operator/ supervisorsection.
GroupReport
Any number of machinescan be put
togetherintoasmanygroupsaspossible.
On-lineMonitoringSystemat Winding
Spinning winding system is totally
equippedwith online quality& produc-
tion monitoringsysterns.Thisworksvery
effectiveandreplacedtraditionaloff-line
monitoringsystem,
There are two type of monitoring sys-
tems that works at autoconer control
panel.Thesebothsystemworksindepen-
dentlyf0r quality& producti0nmonitor,
ing and exchangetheir informationwlm
eachothenTheseare:
. Electronicyarn clearerfor quality
monitoring
. AutoconerM.l,C.systemsworks for
productionmonitoring
ElectronicYarnClearer
Electronicyarn clearersarethe most ef-
fectiveon-linequality monitoringtool in
spinning,It is not oniy monitoringthe
yarn defectsbut alsoremovesobjection-
abledefectsandimprovestheyarn qual-
ity lt's measurethe variousyarn defects
very preciouslyand classifu.Following
parametersmay be monitored through
electronicyarn clearers:
I. Classi[icationof seldom occurring
yarndefects
GATEWAYto SpinningIndustry
AuloconerInformator
Latest autoconer systems provide
detdilonline in[ormationfor running
productionasfollows;
1. SingleDrum or Machineproduchon
at anyInstance
2. Machine& ProductionEfficiency
3. CausewiseproducrionDownTimes:
Detail causes wise production
down time availablewith autoconer
systemsin duratjonandinpercentage
oftotaliossesasbelow:
. RedLight:Drumsstoppeddueto
operationalor mechanicalfailure
. Yellow Lightr Drum stoppedfor
packagedoffing
. Recyclingor RepearersCycles:
Repeatercyclingfor splicing
. Splice Failure: No. of splice
failures
. Bobbin ChangeCycles:No. of
bobbinchanges
. RejectedBobbinsrNo.of rejected
bobbins
. Clearercutsper100km.ofyarn
. Clearercutsper kg.ofYarn
. ClearercutsperBobbin
. TensionBreaks
. Yarn BreaksI i,e.Clearercuts +
TensionBreaks+ StopCuts
. TotalYarnJoints
Mosto[ aboveinformationmayobtainin
theirspecifiedunitsor in percentage.
Responsibilityfor 0n-line
MonitoringSystems
Alltheon-linemonitoringsystemseither
availableasan integralpaft of machine
or 0ptionalretrofit attachmentsarevery
expensivepdrtswhichshouldbeproperly
utilized for its purpose& in favour of
organization,Usually responsibility of
on-linemonitoringsystemsis not clear
in spinningmills,whichIeadignoranceof
these multifuncti0n important systems.
Hence responsibility [or "on-line
MonitoringSystems"maybe distributed
asbelow:
All Quality Monitoring System
Qualitycontrol / Assurancedepartment
is responsible to utilized all the
informationproducedby 0n-linequairLy
monitoring systems such as cotton
2.
3.
4.
Periodicdefects
Classificationof foreignmatter
Classificationof yarn joints & its
quallry
5. Detectionofcountvariation
6. Windingdefects
7. Online yarnimperfection
B, Alarms due to bad quality or off
standardcops

5. :'ir;r'lCLINIC
contamination sorters, different Cv's,
A% Lleviation,spectrogramanalysis&
rhickplacesmoniforingIhroughcarding
& RSBDFs,end breaksmonitoringin
throughoutprocesses,Electronicyarn
clearercuts, classi[ication& online
lmperfectionreportfuomautoconeretc'
All Production Monitoring Systems
Allproductionmonit0ringreportsshould
be utilizedby productionsupervisorfor
their referenceas instanceproduction
figures,causesof detentionand quality
deviafionetc.Shiftwise- Machinewise
summary report should be PrePared
with all relevantinformationandshould
bepresentedtospinningmasteror spin-
ningmanagerfordefailanalysis& acfion
Machineoperatorsmay also educateto
read the productionefficiency& down
tlmereport
Maintenance Activities with the Help
ofOn-line SYstems
Maintenancedctivitiesmaysynchronize
with on-linereportsMaintenanceteam
shouldcontinuouslymoniiorCausewise
breaksofvariouspr0cessesandefficien-
cylossesdueto mechanicalfaiiures'
Shiftwisereportmayhelpsmaintenance
manager for planning of preventive
maintenanceactivity.
Advanlagesof 0n-line Monitoring
Systems
. Quick & instance report at any
moment for quality & Productivity
Performance.
. Monitoring of whole Production
quantiw assure 100 %o qualitY
control.
. Assamplesizeistooiargehencemore
reliable& accuratemeasurement
. Qualitystopsensurethatnodefective
qualitYwill beProduced
. Easyfor monitoring,anybodycansee
resultsat anYtime.
. May get better quality & production
by educatingmachineoPerators'
. Bytakingpropermonitoring& taking
timelyappropriatecorrectiveactions
machine down times may reduce
significantly
. Significantly reduce calculation &
SPINNINGSPECIFICMagazine
clericaljob of technicalperson,also
reduceloadofquaiitycontrolteam
. Dependenceson humanand human
errorsavoided.
. Large scaledata storagefor future
referencemaYbePossible
Conclusion
Technologicalup gradation introduced
idst,accurateandinstdnceonline m0ni-
toringsysiemssomeon-linemonitoring
systemsavailablewilh spinningmachin'
eries are integral part of machinesand
someavailableat optionalretr0fitattach-
ment. Accuracyand authenticityof on-
linesysremsshouldbe checkperiodical-
ly. Cottoncontaminationsorters,carctlng
& RSBDF's & winding electronicYarn
clearerssystemsworksaseffectivequal-
ity m0nitoringtools,while singlespindle
moniToring& productionmonitoringar
ring frame and windings provide lot of
informationrelatedto eachpositionfor
quality& productionProperly& system-
aticutilizationof On-linemonitoringpro-
vide significantimprovementin quality
& productivitywith reductionin mont-
toringcost.
o1 c-,--i-- T.-rila< LNnv-Dec 2014