Discussion on Common Fault Situations of Tufting Machine and Causes of Bad Finished Products

Discussion on Common Fault Situations of Tufting Machine and Causes of Bad Finished Products

The tufting machine is a vital equipment in the textile industry and used for creating a pile surface on different fabrics, such as carpets, rugs, and blankets. While it is efficient at producing high-quality finished products, like all machinery, it is prone to encountering several common faults that can negatively impact the quality of products produced. This article will examine some of these situations and investigate the causes of producing bad finished goods.

1. Yarn breakage

One of the most common problems with a tufting machine is yarn breakage, which frequently happens when the yarn runs over sharp components of the machinery like hooks and needles. This is usually brought on by the yarn being stretched and over-tensioned.

However, several other reasons could lead to yarn breakage, such as damaged needles or hooks, an incorrectly adjusted tension or a worn pattern. It's essential to correct yarn breakage as soon as possible to eliminate numerous rejected finished products which could impact the profits of the textile company.

2. An uneven pile height

An uneven pile height in carpeting is an indication of a tufting machine malfunction. This fault is notable not just for the asymmetrical look but also as a result of reduced effectiveness of such carpeting. This can be due to;

- Irregular tensioning of the backing fabric being fed throughout the machine.

- A tracker beam that no longer drives the principal traction assembly creating uneven mobility of the system.

- Incorrect gauge setting of the needles for the loop pile product intended.

The correct settings on all the needed components in the machine have to be validated, and this will eliminate this fault.

3. Pile runs not locked in place

A pile run is loose, and eventually, it will be lost in the fabrication process without being locked in place. Pile runs not locked in place is a prevalent fault that occurs in the tufted carpets manufacturing process. Pile runs that are not locked in place can cause tons of damage to the carpet's surface. It is usually caused by a malfunction in the lance and looper settings. To avoid this, tufting machines must be well calibrated, and the lance and looper settings properly adjusted.

4. Faulty yarn tension

Unstable or faulty yarn tension can be attributed to a breakdown in the proper functioning of a tufting machine. This typically results in producing finished products that are not of the required standard. The primary cause of this fault is an imperfect dial mechanism calibration, which involves incorrect adjustment of yarn tension. Calibration of the machinery's mechanism should therefore be regularly monitored and assessed to avoid faults resulting from bad yarn tension.

5. Excessively high yarn tension

Excessively high yarn tension is usually the result of the single-carry-on of yarn through the machine. Such tension causes yarn breakages, as well as stress on the machine's components and unnecessarily shortens the lifespan of the machine itself. This fault can result in unwanted damage to the backing, making the carpet vulnerable to immediate breakages during usage after production. The tension must be adequately calibrated, enabling it to remain stable throughout the production process as the finished product is manufactured.

Conclusion

Tufting machines are an important part of the textile industry, especially for producing high-quality finished products like carpets, rugs, and blankets. However, they are susceptible to several common faults that can negatively affect the finished product, whether in the form of uneven pile heights or yarn breakages.

These faults can be caused by various issues, such as damaged needles and incorrect calibration of the machine's mechanism. It's essential to monitor and correct these faults as soon as possible to ensure that the finished products remain of the required standard. Correct calibration and regular maintenance of a tufting machine will, in the long run, save textile companies significant amounts of lost profits due to waste from rejected finished products.