USTER Q-BAR 2 monitors the fabric at the earliest point with automatic, in-line inspection.
USTER Q-BAR 2 monitors the fabric at the earliest point with automatic, in-line inspection.

The best way to avoid off-quality is simply not to make it. USTER Q-BAR 2 monitors the fabric at the earliest point with automatic, in-line inspection. Identifying problems here brings enormous benefits, preventing defects and enabling weavers to deliver constant quality and stay competitive in the market.

USTER Q-BAR 2 is best described as a formation monitoring system, because of its ingenious positioning directly at the interface of warp and weft threads. Alarm and stop signals alert the operator to correct problems immediately.

That allows rapid response as soon as a defect appears, avoiding long-running or repeating faults. Early detection reduces second quality and material loss, as well as minimizing the need for post-production checks.

Formation monitoring

Weaving defects can have various root causes. Therefore, USTER Q-BAR 2 provides different algorithms to identify specific defects and their causes. This inbuilt knowledge can prevent defects within the weft insertion cycle.

Its enhanced detection position in the fabric formation zone means the warp is monitored even before it is traversed by the weft. It allows detection of incorrect warp positions, missing warp, loose warp ends and even pattern irregularities.

Another important innovation is the control of weft irregularities. By monitoring each inserted weft in the formation area, USTER Q-BAR 2 primes users to react to weft irregularities at the earliest possible stage. At this point, it can detect weft-related defects such as double picks, broken weft or slubs and loops.

Total supervision

Defects that become visible only in the woven fabric are the nastiest threat. Often, it’s too late when defects such as reed marks, dirty yarns or floats are spotted. The fabric inspection algorithms of USTER Q-BAR 2 detect even “invisible” defects in the fabric.

USTER Q-BAR 2 also monitors critical machine units in the formation zone. If there is a problem here, the system makes it easy to identify and eliminate it, preventing further defects and again maximizing fabric yield.

Another element of the total supervision provided by the formation monitoring system is its special focus on the selvedge area. This is not only critical for an efficient weaving process, it is also important in further process steps.

Specific algorithms detect irregularities in the selvedge, as well as broken leno and any pattern defects. Continuous pattern monitoring flags up incorrect patterns at the earliest stage, so the loom can be stopped and the problem fixed before many meters of fabric are wasted.

In addition, the system has a permanent eye on the fabric width, an essential factor for further processing. USTER Q-BAR 2 provides continuous width measurement of the woven fabric, from loom setup to full roll.

Designed for users

USTER Q-BAR 2 is highly developed in many other aspects. Its industrial design is ergonomic, and users have easy access to all important parts. It can be installed easily on existing weaving machines.

The system features integrated LEDs and the positions of detected defects are shown by red lights. The improved hardware platform is capable of handling high loom speeds and is ready for future innovations.