A yarn sizing machine sensor acts as a “magic eye” that helps the system automatically adjust technical parameters with precision. The application of modern sensors is a vital factor in ensuring that the yarn after sizing meets the highest weaving standards.
1. Yarn Sizing Machine Sensor for Moisture Control (Moisture Sensors)
Moisture is the most important parameter after the yarn passes through the drying cylinders. A yarn sizing machine sensor measuring moisture helps prevent yarn from becoming too dry, which causes brittleness, or too wet, which causes mold, directly affecting elasticity.
1.1. Detailed Resistance and Capacitance Measurement Mechanism
Most types of yarn sizing machine sensor today use the principle of measuring electrical resistance or the capacitance constant of the yarn. When the water content in the yarn changes, its conductivity and dielectric constant also change according to a certain linear ratio.
The sensor will transmit this analog or digital signal to the central processor to adjust the machine speed or the temperature of the drying cylinders. If the yarn is too moist, the yarn sizing machine sensor will command a speed reduction so the yarn has more time to evaporate water in the high-heating area.
Conversely, if the yarn shows signs of being “scorched” due to being too dry, the system will automatically increase speed or lower the steam pressure in the drying cylinders. This timely intervention helps protect the molecular structure of the yarn, keeping it from becoming brittle, snapping, or accumulating static electricity in subsequent stages.
1.2. Optimizing Drying Energy and Efficiency
Installing an accurate yarn sizing machine sensor for moisture measurement helps the factory save a large amount of steam and electricity consumption every month. Instead of drying at a fixed temperature based on intuition, the machine only heats enough to reach the target moisture (usually 6% to 8% depending on the yarn type).
This not only reduces operational costs but also protects the equipment from overheating. A yarn sizing machine sensor ensures that the output yarn quality is always consistent, regardless of changes in the external temperature and humidity of the machine room.
Furthermore, good moisture control helps improve the adhesion of the size layer. Yarn with standard moisture will absorb sizing chemicals better, creating a tough protective film that helps the weaving process take place smoothly with the lowest number of machine stops.
2. Yarn Sizing Machine Sensor for Tension Control (Tension Sensors)
Stable yarn tension is a prerequisite for ensuring the yarn does not deform, overstretch, or lose its natural elasticity. A yarn sizing machine sensor measuring tension is usually installed at sensitive transition positions.
2.1. Monitoring Tension at the Let-off and Winding Areas
At the input, a yarn sizing machine sensor monitors the tension of thousands of warp yarns from the creel. If the tension is uneven between the warp layers, the sizing film will penetrate inconsistently into the yarn core, causing “wrinkling” or striping in the fabric after completion.
At the headstock area, a yarn sizing machine sensor ensures the yarn beam is wound with precise tension according to a pre-set program. This helps the yarn beam achieve moderate compression, neither being too loose, causing yarn tangles, nor too tight, causing warp yarn deformation.
Using a yarn sizing machine sensor of the Load Cell type helps measure extremely small impact forces with millivolt sensitivity. This signal directly controls the electromagnetic brake system or the motor inverter to immediately compensate for tension when the machine changes speed.
2.2. Preventing Sudden Yarn Breakage and Protecting Surfaces
When yarn becomes jammed at the comb or if tension spikes abnormally, the yarn sizing machine sensor will immediately send a warning signal or stop the machine in an emergency. This prevents mass warp yarn breakage, avoiding long machine downtimes for manual yarn knotting.
The precision of a yarn sizing machine sensor protects the yarn surface from being scratched or frayed due to excessive friction with guide bars or rollers. This is a key factor in maintaining the gloss, smoothness, and high aesthetics of the fabric product.
Good tension control also helps maintain the accurate length of the yarn. If the yarn is overstretched during sizing, it will shrink unevenly after leaving the machine, affecting the fabric width dimensions and fabric weight per square meter (GSM).
3. Yarn Sizing Machine Sensor for Level and Concentration Control (Level & Concentration Sensors)
For the size layer to adhere evenly to the yarn surface, the liquid level in the size vat and the chemical concentration must always be in a state of dynamic balance. A yarn sizing machine sensor in the vat area helps automate the supply of the solution.
3.1. Ultrasonic and Proximity Sensors for Level Measurement
The yarn sizing machine sensor uses ultrasonic technology to determine the distance to the sizing solution surface without contact. When the size level drops below the specified threshold, the solenoid valve will automatically open to supplement more solution from the central cooking pot.
Maintaining a stable size level helps the yarn immersion time in the solution always be 100% consistent. If the size level changes, the hydrostatic pressure acting on the yarn will differ, leading to deviations in the size pick-up content between yarn sections.
The ultrasonic type of yarn sizing machine sensor has a major advantage of not being corroded by chemicals, avoiding adhesion phenomena that cause false readings. This device helps the system operate continuously without manual intervention from workers to check the size level.
3.2. Controlling Viscosity, Temperature, and Solution Concentration
Modern sizing machines are often equipped with additional yarn sizing machine sensor units to measure viscosity and refractive index to control solids concentration (calculated in Brix degrees). Viscosity changes with temperature and cooking time, greatly affecting the penetration capability of the size.
The yarn sizing machine sensor will monitor these indicators to adjust the amount of steam supplied to the vat or the amount of additional dilution water. As a result, the sizing film surrounding the yarn always has a technical standard thickness for each different yarn count.
Additionally, a temperature sensor at the size vat ensures the sizing solution is always kept at an optimal temperature (usually 90-95 degrees Celsius). If the temperature drops, the size will thicken, adhering too much to the yarn and causing hardness and brittleness; the sensor will send a signal for the system to supply heating steam in time.
4. Yarn Sizing Machine Sensor in Speed Control and Automation (Speed & Automation)
Machine running speed must be fully synchronized between parts to avoid yarn slack or sudden stretching. An encoder type of yarn sizing machine sensor plays a pivotal role in this.
4.1. Multi-axis Synchronization with Encoders
A rotary encoder type of yarn sizing machine sensor is installed on the shafts of the inverter motors. It sends pulse signals back to the PLC to calculate the linear speed of the yarn at each segment: from let-off, through the size vat, through the drying cylinders to the winding unit.
Synchronization thanks to the yarn sizing machine sensor helps completely eliminate yarn slippage on the guide rollers. This is extremely important for fine yarns or yarns with high elasticity, where even a small deviation in speed can ruin the yarn.
This sensor system also allows the machine to perform creep speed modes when knotting yarns or high-speed running during normal production smoothly, without changing the physical and chemical properties of the sizing layer on the yarn.
4.2. Length Counting and Production Management
A yarn sizing machine sensor helps accurately measure the length of the yarn that has been sized and wound onto the beam. This information is displayed directly on the HMI screen, helping the workshop manager monitor production progress and manage raw materials precisely.
Thanks to the yarn sizing machine sensor, dividing yarn segments to weave different fabric samples on the same beam becomes easy. The system will automatically stop the machine or signal when reaching the pre-set length, minimizing errors caused by humans.
5. Common Errors and Troubleshooting for Yarn Sizing Machine Sensor
During long-term operation, a yarn sizing machine sensor may encounter some technical problems due to impacts from the harsh production environment. Recognizing early signs of error helps protect yarn quality.
5.1. Signal Noise and Parameter Deviation
One of the common errors is the yarn sizing machine sensor returning flickering signals or continuous number jumping. The cause is usually loose signal wires, electromagnetic interference from high-power inverters, or cotton dust accumulating too thickly on the probe.
The solution is to re-check the grounding system and apply anti-interference shielding for the signal cables of the yarn sizing machine sensor. Regularly clean the laser reading eyes or ultrasonic probes with clean compressed air to ensure the signal transmission path is not obstructed.
If the measured parameters deviate from reality (e.g., moisture measured at 10% but the yarn is actually very dry), it is necessary to perform zero calibration and span calibration for the yarn sizing machine sensor according to the manufacturer’s procedure.
5.2. Damage Due to Corrosion and Overheating
A yarn sizing machine sensor installed near the size vat or drying cylinders is frequently subject to the impact of hot steam and corrosive chemicals. Over time, the protective rubber gaskets may age, leading to moisture penetrating the internal electronic circuits.
The signs of recognition are the yarn sizing machine sensor hanging, not responding, or reporting an “Error” on the screen. In this case, it needs to be replaced with sensor lines having IP67 or IP68 protection standards to increase environmental resistance.
To prevent this, additional heat shields or stainless steel protective covers should be installed for the yarn sizing machine sensor. Periodically checking the physical condition of the sensor housing helps early detection of cracks to handle them before damage spreads inside.
6. Industry 4.0 Standard Yarn Sizing Machine Sensor Installation and Maintenance Process
Technically correct installation from the start is the decisive factor for the accuracy and lifespan of the yarn sizing machine sensor throughout the product life cycle.
6.1. Selecting the Optimal Installation Position
The installation position of the yarn sizing machine sensor must ensure it represents the parameter to be measured for the entire machine width. For example, the moisture sensor should be placed at the position where the yarn leaves the last drying cylinder but before being wound onto the beam, where the yarn temperature is most stable.
It is necessary to avoid installing a yarn sizing machine sensor in places with excessive mechanical vibration or swirling airflow from the ventilation system, as this can skew ultrasonic or tension measurement results. The sensor bracket must be sturdy and flexibly adjustable.
For a tension measuring yarn sizing machine sensor, the roller shaft must be perfectly dynamically balanced and have no mechanical play. Just a small eccentricity will create false signal oscillations that make the control system unstable.
6.2. Preventive Maintenance Plan
Businesses should build a maintenance checklist for the yarn sizing machine sensor every week. Content includes: cleaning the probe surface, checking the tightness of plugs, and using a light to check if lead wires have been bitten by rodents or if the sheath is damaged.
Quarterly, it is necessary to coordinate with the yarn sizing machine sensor supplier to perform deep calibration. Using standard samples to check accuracy ensures the system always operates within the allowable error of textile industry ISO standards.
Storing maintenance records for the yarn sizing machine sensor on management software helps track breakdown history. From there, management can make decisions for preventive replacement before the sensor reaches the end of its lifespan, avoiding sudden machine stops that cause economic damage.
7. The Importance of Periodic Yarn Sizing Machine Sensor Calibration
No matter how modern a sensor is, periodic calibration is mandatory to ensure that the numbers displayed on the control screen are absolutely accurate and reliable.
7.1. Avoiding Errors Due to the Production Environment
A textile factory environment always has the presence of fine cotton dust and high concentrations of chemical moisture. These agents easily adhere to the optical surface or electrodes of the yarn sizing machine sensor, causing false signals or reducing measurement sensitivity.
Technicians need to clean the probe of the yarn sizing machine sensor periodically with specialized non-corrosive cleaning solutions. Checking with standard handheld measuring devices to compare results is the most effective method today.
An error of just 0.5% from a yarn sizing machine sensor can accumulate into a major fault over tens of thousands of meters of yarn, leading to the ruin of an entire export order worth billions of VND. Therefore, the calibration process needs to be performed seriously by specialized personnel.
7.2. Application of Wireless Technology and IoT in Management
The Industry 4.0 trend is driving the use of yarn sizing machine sensor units integrated with wireless connectivity (Wifi/Zigbee). Data from dozens of sensors on the machine is centralized to a cloud server, allowing for remote yarn quality monitoring.
IoT technology helps analyze historical data from the yarn sizing machine sensor using Artificial Intelligence (AI) to provide predictive maintenance forecasts. Businesses can know in advance which sensor is about to fail to prepare replacement parts.
This system also allows for automatic quality report generation for each yarn beam. Customers buying yarn can scan a QR code on the beam to review the entire graph of moisture, tension, and speed during the sizing process, creating absolute trust in quality.
8. VieTextile – Genuine Yarn Sizing Machine Sensor Provider
VieTextile is committed to bringing customers the most advanced yarn sizing machine sensor solutions, helping to elevate the Vietnamese textile production process to international standards.
8.1. Diverse and Standard Product Portfolio
We provide a full range of yarn sizing machine sensor types: from moisture sensors, tension sensors, level sensors, to encoders and temperature sensors. Products are imported genuinely from textile technology powerhouses such as Germany, Italy, and Japan.
When choosing a yarn sizing machine sensor at VieTextile, customers are thoroughly consulted by a team of engineers on technical parameters to ensure 100% compatibility with the existing machine system, whether it is a new model or a used machine.
We do not just sell individual devices but also provide full-package automation control system upgrade solutions. VieTextile helps businesses make old machines smarter thanks to an accurate yarn sizing machine sensor system.
8.2. After-Sales Service and 24/7 Technical Support
VieTextile establishes a long-term and flexible warranty policy for every yarn sizing machine sensor device. We understand that every hour the machine stops is a major loss, so we always have a stock of replacement parts ready for immediate replacement.
Our technical support service operates continuously, ready to be present at your factory to handle yarn sizing machine sensor incidents as quickly as possible. Dedication and professionalism are the guiding lights that help VieTextile affirm its position in the market.
We also organize periodic training courses for customers’ technical staff on how to use, install, and maintain the yarn sizing machine sensor. VieTextile wants every customer to become an expert mastering their own equipment.
8.3. Commitment to Companionship and Sustainable Development
VieTextile constantly researches the latest technologies in yarn sizing machine sensor units to advise customers on superior improvements. We aim to help businesses reduce production costs and improve product quality.
Customer success is the motivation for us to perfect our yarn sizing machine sensor supply service every day. VieTextile is proud to be a strategic partner for hundreds of large and small weaving factories across the country.
We believe that the correct and sufficient application of high-quality yarn sizing machine sensor types is the shortest path for the Vietnamese textile industry to advance deeply into the global supply chain, meeting the most stringent standards of the EU and US markets.
9. Frequently Asked Questions about Yarn Sizing Machine Sensor (FAQ)
Below are answers to common customer inquiries regarding the application, operation, and selection of sensors in the warp yarn sizing process.
9.1. Which type of yarn sizing machine sensor is the most important for quality control?
Every sensor has its own role, but the yarn sizing machine sensor measuring moisture and tension is usually considered the most important. These are the two parameters that directly determine the tensile strength and friction resistance of the yarn on high-speed weaving machines.
9.2. What is the average lifespan of a yarn sizing machine sensor?
If installed technically correctly and maintained periodically, a high-end yarn sizing machine sensor can operate stably for 5 to 10 years. However, parts in direct contact such as the moisture probe should be checked for sensitivity annually.
9.3. Can sensors be added to older generations of yarn sizing machines?
Absolutely. VieTextile specializes in designing solutions to integrate a modern yarn sizing machine sensor into old systems (retrofitting). This helps significantly improve accuracy without needing to invest a large amount of money in a new machine.
9.4. How can one tell if a yarn sizing machine sensor is giving incorrect results?
The most obvious sign is that the parameters on the screen do not match the actual condition of the yarn, or the parameters jump continuously without a pattern. In that case, use a standard handheld measuring device to immediately cross-check with the yarn sizing machine sensor on the machine.
9.5. Does VieTextile provide custom-designed yarn sizing machine sensor units upon request?
We have an R&D team ready to consult and order yarn sizing machine sensor types with specific parameters for difficult yarns such as glass fiber, carbon fiber, or high-technical yarns. Please contact us for the most optimal solution.
To improve production quality and master advanced yarn sizing machine sensor technology, contact VieTextile today to receive in-depth consultation from experts!
Contact Information:
Hotline: 0901 809 309
Email: info@vietextile.com
Website: https://vietextile.com
