On-line sensing of the interlacing process

This thesis deals with the study of the yarn interlacing. The interlacing process is commonly employed by textile industries to impart cohesion points to a multi-filament yarn. Indeed, this work has been realized in the framework of a collaboration between the Department of Physics of the University of Trento (Italy) and Aquafil S.p.A., a company producing Nylon 6 yarn. The interlacing of the filaments into periodic knots is caused by their interaction with a turbolent flow, but the full dynamics is not well characterized. Additionally, one problem that textile industries need to face is the irregularity of the process, still difficult to improve. A regular knots distance is required to ensure the homogeneous appearance of the final fabric. Hence, it is interesting to understand which are the key parameters affecting and influencing interlacing, to improve its regularity. For this reason, the present work focuses on a deeper understanding of the process dynamics. Then, different on-line sensing techniques that measure the knots distance are investigated and compared. The evaluation of the process regularity during yarn production allows, as a further step, to change the machine parameters on-line, avoiding waste of time and material. In Chapter 1 is given the background knowledge about the yarn production process, starting from the raw material. The attention will be focused on interlacing, with an overview of the state of the art literature on that topic. In Chapter 2 the yarn-air interaction is investigated, with a high speed analysis of the yarn motion in an interlacer. A dynamics of interlacing is proposed, indicating the key role played by the turbolent pattern, observed by means of a tracer. Chapter 3 studies the vibrations close to the interlacer, to monitor a possible flow modulation caused by the yarn-air interaction. In Chapter 4 and Chapter 5 two sensing techniques have been approached, based on the use of a microphone and a photodiode. The issues related to those measurements have been investigated, for a final comparison of their performance in terms of capability of detecting the cohesion points distance on-line, on a running yarn.