USTER AFIS PRO - Measurement Principle & Test Results

USTER ® AFIS PRO Measurement Principle Test Results

Measurement Principle

Edas/schulungsunterlagen/AFIS

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Modules • Nep Classification • Fiber neps and seed coat neps • Count and size distribution • Length and Maturity • Length by weight and by number • Short fiber content • Maturity ratio • Immature fiber content • Trash • Dust • Trash • Total foreign matter • AutoJet Edas/schulungsunterlagen/AFIS

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Measurement Principle: Fiber Individualizer


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Measurement Principle: Optical sensors/detectors


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•

Fiber individualizer separates the cotton sample into three main components: Lint Fibers, short fibers, neps, seed coat neps


Trash

Dust

trash, dust, fiber fragments, very large seed coats with little or no attached fibers

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• • •

The nep module is able to distinguish between neps and seed coat neps Each event (fiber, nep, SCN, ) has its own distinct electrical waveform Each samples waveform is compared to a standard waveform to determine which classification it most resembles


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Measurement Principle Voltage U

Nep signal

Fiber signal

Time t


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Measurement Principle 6

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AREA 4

PEAK VOLTAGE

3

2

THRESHOLD VOLTAGE

1

TIME OF FLIGHT

0

-1 0


50

100

150

9

200

250

300

350

Measurement Principle Length & nep measurement • Optical system • Single fiber measurement • Measured with an opto-electronic sensor • Fiber creates signal/impulse  converted to an

electrical signal  analyzed and evaluated by computer Trash & dust measurement • Separate sensor • Same measurement principle as for the length &

nep measurement Edas/schulungsunterlagen/AFIS

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Nep Module Seed Coat Nep

Measures:  Fiber neps and seed coat neps  Count and size distribution

Fiber Nep Edas/schulungsunterlagen/AFIS

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Nep Module •

Fiber Neps



entanglements of several fibers



generated generated under mechanical mechanical treatment treatment of the cotton cotton fibers during harvesting, ginning, opening and cleaning in the spinning mill



amount depends depends on the cotton cotton origin/va origin/variety riety and harvesting method



neps are mainly reduced in carding and combing



amount of reduction depends on the machinery performance performance and the quality quality the spinning spinning mill wants to achieve


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Nep Module •

Seed Coat Neps



fragments fragments of cottons cottonseed eed that still still have have some fibers attached



created mainly in ginning, when the fibers are separated from the seed



amount depends on the the quality and the aggressivene aggressiveness ss of the ginning process process



removal removal in carding carding is very very difficult, difficult, since since the attached fibers tend to stick with the process


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Nep results

Data Product: 

Nep Nep Cnt/ Cnt/ g – Nep Nep Cou Count nt



Nep [m] – Nep Nep Siz Size e



SCN Cnt/ Cnt/ g – Seed Seed Coat Coat Nep Nep Coun Countt



SCN [m] - Size ize


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Nep Classification Histogram

Nep Count per gram

Size ( m)

Distribution of fiber neps (dark) and seed coat neps (shaded) by size ( m)


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Nep Module

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Ranges of Neps and Seed Coat Neps in Raw Cotton (Upland) Neps / gram

Description

< 100

Seed Coat Neps/ gram < 10

101 – 20 200 0

11 – 20

Low

201 – 30 300 0

21 – 30

Medium

301 – 45 450 0

31 – 40

High

> 451

> 41

Very high


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Very low

Length Module Meaning and significance of fiber length: 

Fiber length is one of the most important characteristics of cotton



Defines the spinnability of the fiber



Basis for cotton trading



AFIS length measurement targeted towards process control of spinning mill

USTER ® AFIS measurements: 

Length by weight and by number in [in] or [mm]



Summary table and histograms


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Length Module

•

Difference between by number and by weight measurement (n) “by number”

(w) “by weight”

4 fibers = 100%

4 fibers = 300 g = 100%

2 short fibers = 50%


2 short fibers = 100g = 33%

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Length Module

•

Difference between by number and by weight measurement

2 Systems

Europe

USA

Johannsen-Zweigle

Suter-Webb

by number

by weight


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Length Module Comparison of the length systems "by number"

"by weight"

Measured

Calculated

Shows the true fiber length distribution in the sample

Biased towards the longer fibers. Longer fibers "weigh" more than shorter fibers

Short and long fibers are treated equally

Result is looking "better" than the "by number" results.

gives more accurate results for the optimization of the processes in spinning

used by mills that are used to the results of the comb sorter array methods such as the Suter-Webb-Ar S uter-Webb-Array ray  UQL is close to the classer’s staple 




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Length Measurement

Leng Le ngth th by weigh eightt Le Leng ngth th by nu numbe mberr


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Length Measurement: Data Product Length distribution by weight: L (w)

Mean length (weight) of the fibers in the sample

L (w) (w) CV [%]

Variat Variation ion of tthe he fiber fiber len length gth around around aver average age (weig (weight) ht) [%]

SFC (w) [%]

Short Fiber Content in [%] of all fibers below 0.50 inches or 12.7 mm (weight)

UQL (w)

Upper Quartile Length (weight); length of the longer 5% of all fibers in the sample

Length distribution by number: L (n)

Mean length (number) of the fibers in the sample

L (n) (n) CV [%]

Variat Variation ion of the fiber fiber length length around around averag average e (nu (numbe mber) r) [%]

SFC (n) [%]

Short Fiber Content in [%] of all fibers below 0.50 inches or 12.7 mm (number)

L (n) 5%

The 5% Length (number); length of the longer 5% of all fibers (number)


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Length Measurement • Graphic representation of the length values in the

staple diagram

Fiber length

Short fiber content SFC (n, w)

L2,5%(n) L5%(n) UQL(w)

L (n,w) L½"

0%


25%

50%

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100%

Length (w) Report Length (w)

L(n) L(n) [in]

Distribution of fiber length (dark) and short fiber content (shaded) by weight


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Length (n) Report Length Length (w)

L(n) [in]

Distribution of fiber length (dark) and short fiber content c ontent (shaded) by number


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Length Module: Short Fiber Content • Cotton length is determined by variety • first length development, then development of the

walls 

initially, the fibers have more mo re or less the same length



length is reduced with any mechanical treatment (harvesting, ginning, opening, cleaning)

• mainly reduced at combing • control of the SFC very important for the spinning

performance and the yarn quality Edas/schulungsunterlagen/AFIS

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Length Module • Ranges of Short Fiber Content (w) and (n) in Raw Cotton (Upland) Short Fiber Content (number) < 18

Short Fiber Content (weight) <5

Description

19 – 23

6–8

Low

24 – 28

9 – 11

Medium

29 – 33

12 – 14

High

> 34

> 15

Very high

Very low

* For long staple cottons, other values apply. The T he differences are smaller.


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Maturity Module Measures:

• Maturity ratio • Fineness • Immature Fiber Content • Summary table and histograms


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Fiber Maturity After length development, cellulose is deposited inside the hollow fiber:  fiber is maturing  maturity maturity = degree of cell wall thickness thickness = amount of cellulose inside the fiber


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Fiber Maturity  Calculation of the fiber maturity Perimeter P

Perimeter P

Lumen

Area A2

Area A1

To calculate the mean degree of thickening theta, a circular cross-section of the measured fiber having a perimeter P is calculated, and subsequently area A1 is divided by area A2. Edas/schulungsunterlagen/AFIS

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Fiber Maturity  Calculation of the fiber maturity

Example Cumulative percent

Theta

Frequency

Mature fibers (R)

Thinwalled fibers

Immature fiber content (IFC)


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Fiber Maturity  Calculation of the fiber maturity For this example, the following apply: Mature fiber content R

= 37.6%

Immature fiber content IFC

= 10.3%

Maturity (according to Lord): M


R - IFC 200

 0.7 

37.6 10.3 200

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 0.7  0.83

Fiber Maturity Measurement • AFIS measures the fiber shape • Each fiber is measured from two different angles by

the optical sensor • Depending on the shape, cotton fibers are divided

into: • Fully mature mature - typical typical convolutions convolutions of of a mature mature fiber • Immature Immature - less obvious obvious convolutions convolutions,, more flat flat • Dead - no convolution convolutions, s, completely completely flat, “ribbon “ribbon like”


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Immature Fiber Content • IFC = Immature Fiber Content

Percent of all fibers within a cotton sample that have a cell wall thickness  25% of the full area • Effects of immature fibers

Dyestuff is deposited in the cellulose  immature fibers: no cellulose for the dyestuff to remain 

color differences, barré, white specs!


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Fiber Maturity Measurement Convolution Convoluti on of mature cotton fibers


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Fiber Maturity Measurement Cross-section of mature cotton fibers


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Fiber Maturity Measurement Mature and immature cotton fibers


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Fiber Maturity Measurement Immature cotton fibers


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Fiber Maturity Measurement Immature fiber nep in the fabric (shiny nep)


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Fiber Fineness [mtex]

• Determined optically by analyzing the fiber shape

passing the sensors • Algorithm determines fineness based on the shape

and form of the fibers and their specific weight • Mature fibers contain more cellulose  heavier


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Fiber Maturity Medium perimeter & “fairly mature”

Large perimeter & “well mature”

Small perimeter & “fairly mature”

Medium perimeter & “less mature”


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Maturity Measurement

Data Product: Fine Fine mt mtex ex Fine Finene ness ss [m [milillilite tex x] IFC [%] Immature Fiber Content [%] Matt Rat Ma Ratio io Ma Matu turi rity ty Rati Ratio o [%] [%] Edas/schulungsunterlagen/AFIS

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Maturity Report

[%]

Maturity

Distribution of fiber cell wall thickness (dark) and immature fiber content (shaded)


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Fineness Report

Fineness [mtex]

[%]

Distribution of fiber fineness (mtex)


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Maturity Module

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Ranges of Maturity, IFC and Fineness in Raw Cotton (Upland) Immature Fiber Content (%)

Fineness

< 0.75

<6

< 150

Very low

0.76 0.76 – 0.85 0.85

6–8

151 15 1 – 16 160 0

Low

0.86 0.86 – 0.90 0.90

9 – 11

161 16 1 – 17 170 0

Medium

0.91 0.91 – 0.95 0.95

12 – 1 4

171 17 1 – 18 180 0

High

> 0.95

> 15

> 180

Very high

Maturity Ratio


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Description

(mtex)

Trash Module Measures: • Dust particles smaller than 500 microns • Trash particles larger than 500 microns • Summary table and histograms • Count and size distribution


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Trash Module • Definition Trash:

“foreign” “foreign” particles, particles, i.e. i.e. not related related to any physical properties of cotton fibers. ITMF Definition

Dust Respirable Dust

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Trash

Micro Dust

Trash

Dust

500

20

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Particle Size [ m]

Trash Module

Data Product: Total Cnt/ g Mean Size Dust Cnt/ g Trash Cnt/ g VFM [%] Edas/schulungsunterlagen/AFIS

Count of all particles per gram Mean size of all particles [m] Dust particle count per gram Trash particle count per gram Visible Foreign Matter [% by weight ] 48

Trash Module: Trash Report

Particle Count per Gram

Size [ m]

Dust

Trash

Distribution of dust (dark) and trash (shaded) by size (m)


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Trash Module

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Ranges of Trash, Dust Content and Visible Foreign Matter in Raw Cotton (Upland)

Trash Count/ g

Dust Count/ g

V.F.M.%

Description

< 25

< 200

< 0.60

Very low

26 – 7 5

201 20 1 – 35 350 0

0.61 0.61 – 1.20 1.20

Low

76 – 110

351 35 1 – 60 600 0

1.21 1.21 – 2.30 2.30

Medium

111 11 1 – 15 150 0

601 60 1 – 10 1000 00

2.31 2.31 – 3.00 3.00

High

> 151

> 1001

> 3.01

Very high


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Trash Module • The amount of trash / dust particles in raw

cotton cotton dep depend ends s highly highly on: • origin of the cotton • harvesting method • soil conditions

• The amount of trash / dust particles in cotton

in the processes processes in the spinning spinning mill mill depends depends highly on: • the performance of the machinery • suction systems


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USTER AFIS PRO - Measurement Principle & Test Results

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