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Fibre Measurements

HVI & AFIS


Prof.Dr.S.Kathirrvelu
EITEX-BDU

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AFIS is a modular device intended for testing and


analysing of 100% cotton samples in the form of
bale, opened and cleaned material (card mat),
sliver and roving.
This device belongs to high-efficiency testing
lines

frequently

called

HVI

(high

volume

instrument).
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The history of such devices started in 90s Zellweger Uster launched the first devices
specialized to neps analysing.
Thanks to further development at present
AFIS offers also other modules, from which L
(length) and T (trash) modules are most
widely used.
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The main advantage of AFIS device is testing without


application of any clamps - fiber strand (ca 0,5 kg, 30 cm)
is delivered to opening mechanism, where the strand is
open up to individual fibres, which are measured by
different sensors.
Standard testing procedure contains five partial tests,
test result represents mean value and (and variation) of
measured parameter.
N&L&T modules and can measure neps, length
parameters and trash and parameters.
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N Module
- nep count per gram fibre neps + seed coat neps
- nep size [micron] fibre neps + seed coat neps
- SCN /g seed coat nep count per gram
-SCN size seed coat nep size
T Module
-

Total Cnt/g trash count per 1g

Cnt/g trash count per gram (particle size > 500m)

Dust Cnt/g dust count per gram (particle size < 500m)

Mean Size &- VFM % - visible foreign matter (dust and trash
content in %) suitable parameter for sample comparison
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ADVANCED FIBER INFORMATION SYSTEM (AFIS)


Introduction:
In textile industry raw material is the most dominant factor as it
contributes 50-75% in total manufacturing cost.
In quality conscious scenario, quality of raw material plays a vital role.
But the quality of raw material is decided by measuring its properties.
Now measurement through conventional techniques is very laborious
and time consuming.
Hence the researchers focus their attention towards the inventions of
such instrument, which gives accurate and quick result and one of the
wonderful development is AFIS - Advanced fibre information system.

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BASIC PRINCIPLE of AFIS:


The AFIS method is based on aeromechanical
fibre processing, similar to opening and carding,
followed by electro-optical sensing and then by
high speed microprocessor based computing
and data reporting as shown in Figure.

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A fibre sample is introduced into the system and is


processed through a fibre individualizer, which aero
mechanically separates the sample into three
components consisting of cleaned fibre, micro dust,
and trash.

Each of these components is transported in a


separate pneumatic path and may be analysed
electro-optically or by other means.

The data processing and reporting are handled by


an industrialized PC.

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AFIS provides basic single fibre information and


is distinguished from earlier and existing
methods by providing distributions of the basic
fibre

properties.

These

distribution

measurements provide more accurate, precise,


and basic information about fibre.

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Fibre individualizer:

The fibre individualizer (in Figure) uses


unique cleaning and separating techniques to
present the fibres pneumatically to the
electro-optical sensor.

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1.

The fibres are opened and cleaned using specially designed, pinned and perforated cylinders,
which are similar to open end spinning beaters and stationary carding flats.

2.

Airflow into the perforations of the cylinder allows for thorough engagement and efficient
dust and trash removal.

3.

A specimen of fibre is hand teased into a sliver-like strand and is inserted into the feed
assembly.

4.

It passes between a spring-loaded feed roll/feed plate assembly and is engaged by the pinned
and perforated cylinder.

5.

The fibres are combed and carded; dust is released and removed through the perforations in
the cylinder.

6.

Trash is released after the carding action by the "counter flow" separation slot.

7.

Heavy trash particles are separated from fibres and transported out of the system, whereas,
the smaller dust and fibres are returned to the cylinder aerodynamically by the air drawn into
the slot, thus the term "counter flow slot".
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A secondary stationary flat is used to further


clean and comb the fibres. They are then directly
transferred to a second cylinder.
A second "counter flow" slot removes additional
trash. Its counter flow air is used to transport
fibres out of the system after a final combing
from a third stationary carding flat.
The separated components (cleaned fibre, micro
dust and trash) are transported along three
different production paths.
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Fibre individualizer motor/Motor controller:

Versions 3 and 4 units have a separate drive motor for


fibre individualizer.

These brushless DC motors are noiseless in operation,


allow for direct monitoring and control of the motor
speed, and are easier to service and replace.

The brushless DC motor has its own motor controller


board which monitors and controls and motor speed.

The motor speed can be adjusted by a potentiometer


located on the board.
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Feed motor/Motor controller:

Versions 3 and 4 units feed belts and feed rollers are driven
via worm gear with a stepper motor.

The motor speed is variable from 140 steps/sec to 1116


steps/sec.

The feed motor controller is a motor driver that accepts


pulses and direction information from the control board.

The initial direction of the stepper is determined by the


orientation of the motor's 7-pin plug on the controller.

If the direction is "backward" after installation, reverse the


plug.

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Sliver detector:

The sliver detector is located between the feed tray and feed

plate.

Its function is to signal the control system when sliver is being presented to the
individualizer and when sliver is no longer present.

The sliver detector consists of an infrared LED source and detector.


During operation, the sliver (fibre specimen) passes between the source and
detector 'breaking" the beam which signals the control board to slow the feed rate
to the sampling speed.

When the trailing end of the sliver passes through the source/detector the beam
is "made" once again.

A 15second delay is triggered to allow the remaining sliver to continue processing


through the system before the "end of sample" sequence is initiated by the control
board.
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Electro-optical sensors:

The electro-optical (E-O) sensors consist of


three basic elements tapered entrance and
exit nozzles (on Version 4 lint sensor, a single
piece accelerating nozzle) beam forming and
collection optics.

The detection circuitry (in Figure).


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Individualized fibres (and neps) are transported


pneumatically from the fibre individualizer by an air
stream.
They enter the E.O. sensor through an accelerating
nozzle which straightens, separates, and aligns the
fibres in proper orientation to the source detector.
The fibres penetrate a collimated beam of light and
scatter and block that light in proportion to their
optical diameter and in direct relation to their time
of flight through the sampling volume.
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Generally, rectangular waveforms are produced by the


light scattered by individual fibres. Nep signals are much
greater in magnitude and duration and generate a
characteristic nep "spike". Trash particles produce smaller
spiked waveforms, which are distinguishable from neps in
magnitude and duration.

From these waveforms, which are microseconds in


duration, the pertinent data are acquired, analyzed and
stored in the host computer. Distributions based on size,
length or diameter can be generated.
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DATA ANALYSIS:
I) Lengths by number (n):
Fibre length by number is the length of the
individual fibres. This method measures the
length of each fibre and places them into length
categories.
These categories are added together to obtain
the length measurement for short fibre and
average or mean length.
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Length by number measurements is pure measurements


that are not influenced by the weight of the fibres.
Typically this means that the length by number results are
always shorter than the same sample tested using the by
weight method.
In textile processing, it is recommended that the length by
number be used to determine machine and equipment
settings and also to determine fibre damage as
represented by short fibre content.
Instrument such as the AFIS is capable of providing the
length by number information.
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The Advanced Fibre Information System (AFIS) was


developed

to

measure

traditional

fibre

neps

(entanglements) often times called mechanical neps.


A recent breakthrough development has furthered the
technology for classifying neps into two categories fibre
neps and seed coat neps. AFIS nep classification is the
newest addition to the modular AFIS system providing a
more detailed summary of nep type imperfections from
ginned cotton through carded and combed sliver.
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III) Seed coat nep detection method:


1.

The lint channel contains fibres, short fibres, mechanical neps and seed
coats with fibres attached.

2.

The trash channel contains trash, dust, some fibre fragments and very
large seed coats with little or no attached fibre.

3.

The seed coats, which remain with the fibre during opening are termed
seed coat neps by the AFIS.

4.

These are masses that are most likely to remain with the good fibre
during the textile opening, cleaning, carding, and combing processes.

5.

Large seed coats, termed seed coat fragments, are collected in the
trash port of the AFIS and are more easily removed from the fibre.

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The AFIS nep classification module counts and sizes seed coat neps. The classification
module is able to identify the distinct electrical waveforms produced by fibres, fibre
clumps, seed coat neps, etc.

This improved nep module uses a digital signal processor (DSP) to classify all incoming
waveforms and to calculate nep size. Figure illustrates a typical nep waveform and the
values extracted by the standard nep module. Figure illustrates the same signal analyzed
by the DSP system.

The DSP system is capable of recording and analyzing all information contained in the
nep signal, therefore providing better information about the sample characteristics. The
classification software compares each sampled waveform to a standard waveform to
determine which classification it most resembles.

These standard waveforms are based on models of seed coat neps and mechanical neps
travelling through the sensor and are verified on numerous simulations using manually
introduced fibre neps and seed coat neps.
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AFIS APPLICATIONS:
(1) Card nep analysis:
fibres.

Neps are created by mechanical handling and cleaning of cotton

Due to fibre individualizer provided inside the machine we can analyze neps

hence we can check nep in carded or combed sliver.


(2) Card wire maintenance analysis:

We can judge the grinding frequency required for

card wires by appropriate checking of sliver quality on AFIS instrument.


(3) Length applications :

This instrument will provide various fiber length data so that it

will be helpful to control the imperfection in the final yarn.


(4) Length analysis of comber and D/F:

This instrument provides the data on histogram

i.e. in form of fibre distribution so it will give accurate idea about length.
(5) Trash application::

By using this instrument we come to know the exact amount of

trash present in material so that we can decide the material is suitable for processing or
not.

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ADVANTAGES:
1.

High degree of accuracy, which gives precise


results.

2. Testing speed is high.


3. It avoids laborious time work needed for
measurement of nep count.
4. The results are free from human and machine
error.
5. It can analyze process performance.
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HIGH VOLUME INSTRUMENT TESTING (HVI)


THE BASICS:
The Uster HVI 900 system measures the seven physical
characteristics defined by the United States Department of
Agriculture (USDA) in its cotton marketing system.
The Uster HVI 900 system measures :
1. Fibre length 2. Fibre strength 3. Length uniformity 4.
Elongation 5. Micronaire 6. Color 7. Trash

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BACKGROUND:

The testing of fibers was always of importance to the


spinner.

It has been known for a long time that the fiber


characteristics have a decisive impact on the running
behavior of the production machines, as well as on the
yarn quality and manufacturing costs.

In spite of the fact that fiber characteristics are very


important for yarn production, the sample size for
testing fiber characteristics is not big enough.
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This is due to the following:

The labour and time involvement for the testing of a


representative sample was too expensive. The results were
often available much too late to take corrective action.

The results often depended on the operator and/or the


instrument, and could therefore not be considered objective

One failed in trying to rationally administer the flood of the


raw material data, to evaluate such data and to introduce the
necessary corrective measures.

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Only recently technical achievements have made


possible the development of automatic computercontrolled testing equipment. With their use, it is
possible to quickly determine the more important fiber
characteristics.
Recent developments in HVI technology are the result of
requests made by textile manufacturers for additional
and more precise fiber property information. Worldwide
competitive pressure on product price and product
quality dictates close control of all resources used in the
manufacturing process.
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Objective of Testing
Reasons for Textile Testing:

Checking the quality and suitability of raw material and selection of material.

Monitoring of production i.e. process control.

Assessment of final product, whether the quality is acceptable or not, (how


will be the yarn performance in weaving? etc).

Investigation of faulty materials (analysis of customer complaint,


identification of fault in machine etc.).

Product development and research.

Specification testing: Specifications are formed and the materials are tested
to prove whether they fall within the limits allowed in the specification (e.g.
specified by a customer).
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1.

HVI testing principle


Micronaire: Micronaire Reading Measured by relating airflow resistance to the
specific surface of fibers.

2.

Maturity: Maturity Ratio Calculated using a sophisticated algorithm based on


several HVI measurements.

3.

Length: Upper Half Mean Length, Uniformity Index, Short Fiber Index Measured
optically in a tapered fiber

4.

beard which is automatically prepared, carded, and brushed.

5.

Strength: Strength, Elongation Strength is measured physically by clamping a


fiber bundle between 2 pairs of clamps at known distance. The second pair of
clamps pulls away from the first pair at a constant speed until the fiber bundle
breaks. The distance it travels, extending the fiber bundle before breakage, is
reported as elongation.
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6.

Moisture: Moisture Content Moisture content of the cotton sample at


the time of testing, using conductive moisture probe.

7.

Color: Rd (Whiteness), +b (Yellowness), Color Grade Measured


optically by different color filters, converted to USDA Upland or Pima
Color Grades or regional customized color chart.

8.

Trash: Particle Count, % Surface Area Covered by Trash, Trash Code


Measured optically by utiliz

9.

ing a digital camera, and converted to USDA trash

grades or

customized regional trash standards.

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