U.S. Industry Is A Critical PPE Supplier

By Jim Phillips, Yarn Market Editor

Many spinners and fabricators are continuing to focus resources on providing personal protective equipment (PPE) to help first-line health care workers continue the fight against COVID-19.

For many companies in the fiber/textile/apparel complex, shifting resources from consumer goods to medical textiles has enabled them to weather the COVID crisis better than many other industries. Yet, even at the furious pace at which new products are manufactured, shortages of critical supplies are still common, and, in some cases, are becoming more severe. Part of the problem rests with limited PPE capacity in the United States and an over-reliance on China to fill the gap.

National Council of Textile Organizations (NCTO) President and CEO Kim Glas recently addressed the issue in testimony before the House Ways and Means Trade Subcommittee hearing on “Manufacturing and Critical Supply Chains: Lessons From COVID-19.”

“While domestic textile manufacturers have undertaken heroic efforts to confront the ongoing crisis, the onshoring of a permanent PPE industry will only materialize if proper government policies and other actions are put in place to help domestic manufacturers survive the current economic crisis and to incentivize the long-term investment needed to fully bring PPE production back to the United States,” Glas said. She outlined policy recommendations and concrete steps the government should take to address the long-term and short-term needs of frontline health care workers, patients and the general public.

“The time is ripe for a revival of American PPE textile manufacturing. It has already begun, but we are at a pivotal point. Without the necessary policy response and support, our recent progress will be undone just as quickly, and the China stranglehold over global medical textile supply will be locked in for the foreseeable future with no reason to invest here,” Glas said.

“The U.S. textile and apparel industry is ready, willing, and able to supply our country’s PPE needs now and for what lies ahead,” she added.

Reshoring PPE Production

A multi-industry coalition, representing the full spectrum of domestic PPE production released a statement in late July outlining policy principles and objectives needed for reshoring and safeguarding domestic PPE manufacturing.

The COVID-19 pandemic, which exposed severe shortages in PPE supply and an over-reliance on foreign sourced products, underscores how important it is for the U.S. government to incentivize, support and maintain domestic manufacturing capacity for PPE.

Association members, encompassing every segment of the U.S. textile, apparel and PPE supply chain, as well as unions representing workers, acted swiftly to convert manufacturing facilities and build supply chains virtually overnight to produce desperately needed PPE.

“We are united in our support of important principles that must be adopted in order to address our current public health needs and guarantee our nation is better prepared to respond to future emergencies,” the 21 associations said in the joint statement.

The associations are calling on Congress and the Trump administration to adopt principles outlined in the statement through legislation, executive order and other appropriate means.

Shortages Likely To Continue

Until there is enough U.S. capacity to supply PPE in necessary quantities, periodic shortages are likely to continue. “COVID-19 has put tremendous pressure on medical textile supplies,” said one industry analyst. “And with the worst of flu season coming up, the situation has the potential to become extremely critical. We can’t keep up with PPE needs for COVID. A bad flu season could be catastrophic.”

Recent surges in coronavirus cases have caused PPE needs to become even more critical. The U.S. Food and Drug Administration (FDA) on August 14 revealed its first list of medical supplies that are in short supply. The agency has required companies to report potential supply disruptions since May under the CARES Act.

The list does not reveal the product manufacturers, but lists that ventilators, respirators, masks, surgical gowns, gloves and sterile swabs are on short supply. As of August 14, more than 168,000 people in the United States have died from the virus and its complications,  according to Johns Hopkins University. Overall, more than 5.2 million coronavirus cases have been reported in the United States.

The FDA announcement is in sharp contrast to an announcement by President Trump earlier in the day that lauded the work to increase the Strategic National Stockpile’s supply of some of the products that made the FDA list.

“We have tripled the number of N95 masks on hand to over 40 million, tripled the number of gowns to over 15 million and quadrupled the number of ventilators to 69,000,” Trump said during a news briefing.

While PPE supply shortages were common during the early stages of the pandemic, critical supplies began to increase. However, a spike in cases during August — particularly among those states that had reopened early or that have not implemented strict mask requirements and social distancing guidelines — resulted in additional shortages. Some medical facilities, particularly in rural area, say they have struggled to keep any inventory of critical supplies.

A large national organization that distributes donated equipment, GetUsPPE, said it’s received a massive increase in requests for PPE over the past two months, as the virus walloped the Sun Belt states and spread throughout the country.

There is increasing fear that the PPE shortage will not be temporary. According to The Guardian, shortages of personal protective equipment and medical supplies could persist for years without strategic government intervention.

Officials said logistical challenges continue seven months after the coronavirus reached the United States. Although the disarray is not as widespread as it was this spring, hospitals said rolling shortages of supplies range from specialized beds to disposable isolation gowns to thermometers.

“A few weeks ago, we were having a very difficult time getting the sanitary wipes. You just couldn’t get them,” Dr. Bernard Klein, chief executive of Providence Holy Cross Medical Center in Mission Hills, Calif., told reporters. “We actually had to manufacture our own.”

August 2020

Guess? Inc. Announces Chairman Of The Board Transition

LOS ANGELES — August 14, 2020 — Today, Guess? Inc. announced that Maurice Marciano, co-founder and non-executive chairman of the board of Guess, was recently injured in a bicycle accident near his home in Napa Valley.

Paul Marciano, chief creative officer and director for Guess, commented: “After careful medical review, my brother Maurice will be in rehabilitation and therapy for an extended period of time and, therefore, will no longer continue to serve as non-executive chairman of the board.”

Effective August 14, 2020, the Guess board has appointed Alex Yemenidjian, an independent board member for more than 15 years and the current lead independent director, to replace Maurice Marciano as non-executive chairman of the board. Maurice Marciano will continue in his role as a member of the Guess board.

Paul Marciano added: “All board members, our friends and family, and all members of the Guess Family, wish Maurice a prompt and healthy recovery from this very unfortunate accident. In the meantime, we know that Alex will continue his exemplary service to Guess in his new role as non-executive chairman of the board.”

Posted August 17, 2020

Source: Guess? Inc.

SwaddleDesigns Reports Face Mask Has Been Proven To Be One Of The Most Effective On The Market

SEATTLE — August 17, 2020 — SwaddleDesigns 3-layer cotton mask has been proven to be one of the most effective face masks on the market, according to the company. Designed by Lynette Damir, RN, SwaddleDesigns masks are fitted to minimize leakage around the nose, on the side of the face, and under the chin. Using the most-current research, SwaddleDesigns masks yield superior filtration of aerosolized droplets by using three layers of tightly woven 180 thread count cotton fabric. SwaddleDesigns masks are breathable and comfortable and can be worn for long periods of time without discomfort.

In June 2020, Florida Atlantic University (FAU) researchers developed a Cough Emulator to assess the efficacy of many different face masks. The study shows not all masks are created equal, and some masks are much better than other types of face coverings in stopping expelled droplets.

In July 2020, FAU researchers tested SwaddleDesigns 3-layer Cotton Mask and demonstrated its superior performance in minimizing droplet leakage from the mask and providing excellent filtration.

Watch the video of the “FAU Mask Efficacy Lab Test Results using Cough Emulator” by clicking here: https://www.swaddledesigns.com/pages/video-cloth-mask-lab-droplet-test-cough-emulator-florida-atlantic-university

In April 2020, Wake Forest published a study that concluded that 180 thread count woven cotton was the best fabric for filtration of droplets. In August 2020, Duke University researchers tested 14 masks and concluded that 3-layer cotton masks are the best cloth masks for consumers.

“We are pleased to see schools, public health officials, corporate decision makers, and the media focusing attention on the relative effectiveness and efficacy of face masks. Clearly, not all masks are equally effective, and we are pleased to see our masks continue to perform as one of the most effective masks on the market,” shared Lynette Damir, RN, and founder of SwaddleDesigns.

SwaddleDesigns masks are effective, comfortable, and affordable, so the general public can easily have access to one of the best reusable cloth masks on the market. Orders ship within one business day.

Cloth Face Masks

Posted August 17, 2020

Source: SwaddleDesigns

2020 Louis Schwitzer Award Recognizes Talented Engineers for NTT INDYCAR SERIES® Innovation

AUBURN HILLS, Mich. — August 17, 2020 — The 54th annual Louis Schwitzer Award was presented to eight engineers for their engineering excellence in developing the innovative Aeroscreen for INDYCAR, which protects the driver from airborne debris. The awardees included Ed Collings, Red Bull Advanced Technologies; Antonio Montanari, Dallara; Stefan Seidel, Pankl Racing Systems; Craig McCarthy, Aerodine Composites; Brent Wright, PPG; Marco Bertolini, Isoclima; and Bill Pappas and Tino Belli from INDYCAR. BorgWarner and the Indiana Section of the Society of Automotive Engineers (SAE) International gave the award, along with a $10,000 prize, to the engineers. The award recipients have decided to donate the prize money to SeriousFun Children’s Network.

The Louis Schwitzer Award honors engineers who innovate new concepts to improve competitive potential, with a focus on new technology with applications in the engine, powertrain, profile, chassis or safety, and that adhere to the NTT INDYCAR SERIES  specifications. Judges aim to recognize advancements that increase performance, safety or efficiency.

“A lot of the emphasis for the Indy 500 is put on who will take home the coveted Borg-Warner Trophy®, but we think it’s just as important to highlight the significant efforts of the engineers behind-the-scenes who continue to innovate impressive technologies for the NTT INDYCAR SERIES ®,” said Frédéric Lissalde, president and CEO, BorgWarner Inc. “With safety being at the forefront of everything we do at BorgWarner, we’re pleased to see this group of award winners honored for bringing a creative and functional safety solution to the racing industry.”

Implemented by INDYCAR for the 2020 season to protect the driver from airborne debris, the Aeroscreen is designed to withstand up to 28,100 lbs (125 kN) of vertical and lateral static loads and survive the impact of a 2.2 lb (1 kg) projectile fired at 220 mph (354 kph). A key benefit of the technology is that it has no optical distortion and does not interfere with the driver’s sightlines. Additionally, it allows for ‘straight up’ driver extraction in case of a back injury and is interchangeable with all Dallara DW12 chassis systems.

Consisting of an additive manufactured titanium top frame, a titanium-reinforced carbon fiber lower frame and a clear laminated polycarbonate screen, the top frame prevents large objects from entering the cockpit. Similarly, the lower frame stiffens the cockpit opening and provides attachment points for the top frame and screen, and the screen deflects smaller debris away from the cockpit. The Aeroscreen is the result of a worldwide engineering collaboration between INDYCAR and Red Bull Advanced Technologies (United Kingdom) for the structural design; Dallara (Italy) for the aerodynamic design; manufacturers Pankl Racing Systems (Austria) for the top frame; Aerodine Composites (U.S.) for the lower frame; and PPG (U.S.) and Isoclima (Italy) for the screen.

Beyond celebrating engineering excellence, the award memorializes Louis Schwitzer, who won the first auto race at the IMS in 1909 and designed the “Marmon Yellow Jacket” engine that powered the Marmon Wasp to victory at the first Indianapolis 500 in 1911. After founding Schwitzer Corporation in 1918, Schwitzer led the IMS technical committee and maintained a strong association with SAE throughout his career. BorgWarner acquired Schwitzer Corporation in 1999 to expand BorgWarner’s turbocharger, engine cooling systems and other offerings.

When it comes to the Indianapolis 500, BorgWarner’s heritage runs deep, centering around the famous Borg-Warner Trophy, which has been awarded to the winner of the big race every year since 1936. BorgWarner also is the Official Turbocharger Partner of the NTT INDYCAR SERIES , meaning its EFR™ (Engineered for Racing) turbochargers boost the engine of every car participating in the Indianapolis 500. Built for reliability, the turbochargers deliver an unprecedented combination of advanced technologies including: Gamma-Ti (titanium aluminide) turbine wheels, ceramic ball bearings and stainless-steel turbine housings.

Posted August 17, 2020

Source: BorgWarner Inc.

Thermajane Introduces New Line Of Compression Wear For Women

NEW YORK CITY — August 17, 2020 — Thermajane, an  online thermal-wear apparel brand, has introduced its workout compression wear line to complement its best-selling thermal styles. Featuring shirts, pants, and compression shorts, the affordable new compression collection has been designed with Thermajane’s innovative fabric technology that supports an active lifestyle with total comfort.

Each high-quality piece in the workout compression wear line provides a 360-degree flexible stretch that conforms to fit every women’s unique body without riding up. Thermajane’s innovative fabric technology features moisture-wicking for dryness and cool comfort, whether at the gym or on-the-go.

“Thermajane’s workout compression wear caters to the specific needs of all women with innovative, feminine designs that are functional and affordable while also addressing two of the most common activewear complaints — lines and comfort,” said Michael Shmaya, brand manager. “We are excited to launch this collection which offers women a quality solution that suits an active lifestyle.”

The new line of compression wear is offered in four colors — wine, black, slate and navy — with sizes ranging from XXS to 3XL. Prices range from only $16 to $20, due in large part to Thermajane’s innovative strategy to leverage its large-scale global supply chain and brand strength to offer high-quality apparel at affordable prices.

The debut of Thermajane’s workout compression wear follows the company’s November 2016 launch of its best-selling women’s thermal underwear collection. This latest line represents the company’s next stage of growth, with additional growth anticipated in 2021 as the company expands the line to offer additional colors and styles.

“The launch of our thermal collection was one of the most successful to date, and by adding workout and compression wear we are providing women with total comfort options for their every need,” Shmaya said. “It’s an exciting time for Thermajane as we deliver on our promise for quality, new products, and expansion into this segment of the apparel market.”

Across both collections, Thermajane strives to create exceptional activewear that blends fashion, comfort, and technology while keeping up with the latest trends. Additional details about Thermajane’s new workout compression wear is available online at www.thermajane.com. The e-commerce website provides full product detail for each item which includes men’s and women’s compression and thermal wear, as well as children’s thermal sets.

Posted August 17, 2020

Source: Thermajane

New USTER® STATISTICS Data Offers Competitive Gains — How Spinners Can Improve Quality Consistency And Get The Most Out Of Raw Material

USTER, Switzerland — August 17, 2020 — Uster Technologies offers spinners valuable new insights into yarn quality optimization, thanks to its unique combination of expert monitoring of market trends and comprehensive statistical analysis. For example, there is evidence that fiber elongation depends more on the type of cotton than on fiber length. And not all neps are the same: there are significant gains to be made from differentiating between seed coat and fiber neps.

Both these facts offer spinners potential for competitive advantages, arising from new data categories in USTER® STATISTICS 2018. This global benchmarking tool now includes revealing information about fiber elongation, as well as seed coat and fiber neps, and USTER explains how these can be exploited to improve yarn quality consistency.

Fiber elongation

In conjunction with fiber tenacity, fiber elongation influences yarn elongation and the processing behavior of the yarn, since higher values will typically perform better in the weaving mill. For this reason, it was obviously beneficial to include fiber elongation in the latest Uster Statistics.

Analysis of Uster databases show that the correlation between fiber elongation and yarn elongation of a combed cotton ring yarn is at a level of 85 percent. Although the twist multiplier and yarn production speed have a huge impact on yarn elongation, the basis for high yarn elongation actually comes from the fiber. The elongation of cotton fiber conclusively depends more on the type of cotton than the fiber length.

When engineering laydowns for yarn production, experts know which yarn parameters are influenced by certain fiber properties. It is possible to offset small deficiencies in one fiber property with an improvement in another. If a low fiber length might negatively affect yarn elongation and twist level, a slightly higher elongation in fiber could help.

Seed coat nep or fiber nep?

Ginning mills today increasingly focus on productivity rather than quality. At the same time, gins have not been upgraded to match the increased volumes of cotton. This suggests that a more accurate evaluation of cottons is now advisable for spinning mills. This can be achieved by assessing fiber neps and seed coat neps separately. The distinction between these two types of nep count is now possible in Uster Statistics 2018 — and this allows more detailed analysis and new benefits compared with the previous data covering only the total nep count.

Firstly, the mill can optimize laydowns to manage a specific nep component. It can also optimize the specific nep removal efficiency. The spinner can even predict more accurately the level of white spots showing in fabrics made from the yarn after dyeing. A high level of fiber neps, with a high proportion of immature fibers, can cause these white spots. By analyzing the fiber nep level at the laydown stage, mills can adjust their processes accordingly — for example by focusing on fiber nep reduction during carding.

With Uster Statistics 2018, spinners are recommended to adjust card settings and compare the sliver data with the fiber nep processing chart, to benchmark the data against other mills. Combined with monitoring maturity, spinning mills can avoid or reduce white spots. If these are discovered during processing, the yarn can be redirected into a different application — such as bleached white t-shirts — where immature fiber neps are less disturbing.

Vital data, right instrument

Established in 1957, Uster Statistics are a vital source of quality data for the textile industry and are now newly available as an app. The value of Uster Statistics 2018 is acknowledged worldwide, allowing yarn producers and their trading partners to compare quality levels objectively against global market standards. Testing thousands of samples each year during past decades allows Uster unique market observations — enabling it to adapt the scope of the Statistics accordingly.

For testing and analyzing the critical fiber raw material parameters for cotton spinning, the Uster AFIS PRO 2 is the right instrument. It operates with unmatched accuracy and speed to measure fiber neps, seed coat neps, short fiber content, fineness, maturity, trash and dust — all of which influence yarn performance in manufacturing. That’s why Uster AFIS is the industry standard for process optimization in spinning mills — proven with more than 1,200 installations worldwide.

Optimal laydown recipe

The combination of textile know-how, current statistical data and advanced technology is the basis for consistent yarn quality, despite changing conditions and new trends. David McAlister, product manager Fiber Lab, Uster Technologies, said: “We could consider the laydown mixes used in yarn spinning as a ‘recipe’ and fiber quality parameters as the ‘ingredients’. We would then aim to adjust the ingredients to keep consistency in the recipe. With Uster Statistics 2018, we can determine the relationship of fiber properties to yarn properties and from that we can learn how to adjust the ingredients of the recipe for optimal performance. This is important for cotton, as it is not always possible to obtain the same or similar fiber qualities year-in and year-out.”

Posted August 17, 2020

Source: Uster Technologies AG

Spinnova Appoints International Textile Experts — Prepares To Scale Its Sustainable Fiber Production

JYVÄSKYLÄ, Finland — August 17, 2020 — As fiber innovation company Spinnova prepares to scale its sustainable fiber production, it has recently onboarded two niche textile experts to help commercialize its sustainable wood-based fiber. Spinnova has also appointed four other members to the team.

Mahmood

Shahriare Mahmood has started as Spinnova’s sustainability director. Mahmood joined Spinnova from the renown Finnish children’s wear brand Reima. Mahmood has both an academic and a technical textile industry background. Graduated as a chemical engineer in Bangladesh and Master of Engineering in Finland, Mahmood has also worked in textile mills in Asia and Europe.

In the course of his extensive career, he has specialized in circularity and material research and development, as well as quality and supply chain management. He has also recently earned a Ph.D. in sustainability management. With Spinnova, Mahmood focuses on supporting sustainability efforts of partnering brands and related pre-commercial and commercial phase supply chains.

“Shahriare has experience of many different phases of textile manufacturing. In our team, he gets to personally close the loop. We are excited to have access to his hands-on technology skills and in-depth sustainability knowledge,” said Spinnova’s CEO and co-founder Janne Poranen.

Kim

Spinnova’s other textile expert appointment is Eun (Enja) Young Kim, who started as senior fibre application specialist in Spinnova’s R&D team. Engineer by background, Kim previously worked for fiber technology company Lenzing in Austria, where she worked in technical customer service of technical applications. She will be focusing on developing the Spinnova fiber’s quality and finishings.

“Enja’s vast experience of cellulose-based textile fibres helps us ensure that our fiber succeeds in partnering brands’ supply chains and end products,” Poranen added.

Spinnova has also onboarded four new people in its R&D and laboratory teams. Spinnova now employs 36 people full time.

Posted August 17, 2020

Source: Spinnova Ltd.

Development Of An Eddy Current Sensor For The Detection Of Filament Damage On Carbon Fibers

By Lukas Lechthaler, Thomas Gries, Richard Kupke, Dirk Feltin, Peter Vojcena, Christine Stamm

The aim of the research project “ZIM EddySCARF” is the development of an eddy current sensor, which allows inline, non-contact 100-percent inspection of carbon fiber rovings for quality assurance. The sensor is useful to both carbon fiber manufacturers for outgoing goods inspection and yarn-processors as means of incoming goods inspection and production process monitoring. The eddy current sensor is intended to detect, classify and quantify various defects in carbon fiber processing — gaps, fuzz, undulations, false twists, accumulated or significant filament breaks, for example. The evaluation of the measurement signal is carried out both by classical measurement value analysis and by machine learning algorithms using neural networks. The focus of the development is on the detection of optically invisible defects and their influence on mechanical performance. The economic use of the sensor by scaling is of secondary interest.

Challenges

Carbon fiber reinforced plastics (CFRP) are becoming increasingly important in various fields of application. The largest areas of application are in the aerospace and automotive industries, with the wind energy and sports and leisure sectors also recording growth [CC18]. Quality assurance has already been certified for metallic materials and corresponding test procedures exist. In contrast, both testing and quality assurance of the CFRP process chain are still under development. The quality assurance of carbon fiber (CF) rovings is the sole focus of this project. When a damaged roving is removed early from the CFRP process, no added value is wasted as is not processed into a component. In this way, a suitable test procedure can contribute to increased economic efficiency and resource conservation of the energy- and cost-intensive material carbon.

So far, the quality assurance of carbon fiber rovings has been carried out offline by means of outgoing and incoming goods inspections using destructive testing. These tests are time-consuming and can only be carried out in the form of sampling. Therefore, a carbon fiber bobbin cannot be tested 100 percent, which results in an uncertainty regarding the quality of the goods. In order to realize a 100 percent inspection, non-destructive testing methods can be used, whereby at this time mostly optical sensors are used. A disadvantage of optical sensor systems is that quality assurance can only be performed on the surface of the roving. However, in a 12k roving (see Figure 1) only about 1,900 filaments are on the surface, while the roving consists of a total of 12,000 filaments [Mor05; Sch07].

Figure 1: Estimation of the CF filaments visible on the surface of a 12k roving

Figure 1 shows that optical sensors can only detect around 16 percent of the roving. Defects inside the roving are therefore not detected and remain in the process chain, where they can ultimately lead to waste. Furthermore, CFRP components are heavily oversized due to defects that cannot be detected and for safety reasons. The safety factors for standard components range from j = 1.5 [Sch07] to j = 3 for safety-critical components. These are the direct consequences of defects in the carbon fibre roving caused during processing which cannot be detected with the current state of the art. This thus contributes to the relatively high production costs of CFRP components. One approach to detect hidden filament breaks by optical sensor technology is the use of destructive testing methods. This also allows the inside of the CF roving to be made optically accessible. However, the disadvantages of destructive testing methods, such as test waste of the cost-intensive material carbon and the lack of the possibility for use in inline process monitoring, oppose this approach.

Aim and Approach

Therefore, the aim of the research project EddySCARF is the development and application of a stand-alone, inline filament breakage sensor based on the physical functional principle “eddy current” (EC) (SURAGUS GmbH). The EC sensor is intended to achieve 100 percent inline process monitoring of carbon fiber-based manufacturing processes. This will be carried out using the example of structural components in the aerospace industry for quality-controlled process monitoring and control. The sensor system can be used both by carbon fiber manufacturers  such as Teijin Europe GmbH, and processors including Hightex Verstärkungsstrukturen GmbH or SAERTEX GmbH & Co. KG, all based in Germany. For carbon fiber manufacturers, quality monitoring by means of eddy current is intended to enable a 100-percent outgoing goods inspection. For carbon fiber processors, the aim is to quantify fiber damage along their process chain by using eddy current so that the various sub-processes can be optimized and a 100 percent incoming goods inspection made possible. Figure 2 shows potential applications of the eddy current sensor system at carbon fiber manufacturers and processors.

Figure 2: Possible application of the eddy current sensor in a) carbon fiber production and b) processing

The measuring system can reduce production waste and improve material usage. As a result, the lightweight construction factor of the material carbon is exploited to a greater extent. The sensor’s application possibilities are broadly diversified due to its flexible use along the CFRP process chain by both manufacturers and processors.

Solution

First, the requirements of all project partners for the eddy current sensor system are defined. For this purpose, the requirements of carbon fiber manufacturers, represented in the research project by the Teijin company, as well as those of carbon fibre processors, represented in the project by the companies Hightex and SAERTEX, are taken into account. At the same time, a test bench for validating the eddy current sensor will be developed, manufactured and commissioned at the Institute of Textile Technology. On the test bench, artificial defects similar to those during production and processing can be inserted into a carbon fiber and measured. A so called damaging module will be developed and implemented in the test bench, which allows a reproducible application of the defects, so that the eddy current sensor can be tested here on a laboratory scale. Figure 3 shows a schematic representation of the tribological test bench on which the eddy current sensor is tested.

Figure 3: Schematic diagram of the experimental setup at the Institute of Textiltechnik of RWTH Aachen University for testing the eddy current sensor on a laboratory scale

On the test bench shown in Figure 3, a carbon fiber roving is measured via optical filament breakage sensors to quantify the superficial degree of damage before and after contact with the damaging module. Via the damaging module, defects are automatically and reproducibly inserted to the roving and subsequently detected with the eddy current sensor. By automating the damaging module, both the location and type of the defect are known, so that it can be correlated with the measurement signal of the eddy current signal and compared with the data of the optical filament breakage sensors. The approaches pursued in the project to evaluate the eddy current signal are both in the classical measurement value analysis and in the use of machine learning algorithms using neural networks.

The eddy current sensor itself is developed in an agile and iterative way and follows the four stages of a Deming cycle (See Figure 4). First, the sensor prototype is designed and manufactured by SURAGUS. Afterwards the sensor is validated in laboratory scale at the Institute of Textile Technology as well as with the research partners under real production conditions in an industrial environment. The sensor will be used by the different project partners in different processes. Hightex implements the sensor system in the Tailored Fibre Placement, SAERTEX in the scrim production for the qualitative control of the carbon fiber bobbins and Teijin in the carbon fiber production process and compares the measurement signal with real production data. Finally, improvement measures for the measuring system are derived from the use on a laboratory and industrial scale (4th Act) in order to be able to counter the problems identified in the process. Subsequently, the cycle is run through again in order to realize a progressive improvement of the sensor over the project duration, starting with a first prototype up to an industrially usable sensor system.

Figure 4: Deming cycle for the iterative development of the eddy current measuring system First Results

Initial tests have already shown that filament breaks introduced specifically into carbon fiber rovings lead to a significant deflection in the measurement signal. For this purpose, a roving was damaged on the test bench shown in Figure 3 and the damage applied was measured using a first prototype of the eddy current sensor. The roving was tested at a haul-off speed of 2 meters per minute for 5 minutes per test point and without additional yarn tension. Each test point (a-g) of the preliminary tests in Figure 5 thus corresponds to a tested run length of 10 m carbon fiber and represents approximately 7,000 measuring points.

Figure 5: Visualization of the first results of quality monitoring using eddy current technology

The results of the preliminary tests show a difference between the measured values of the damaged areas (a, c, f) and the undamaged areas (b, e, g). The magnitude of the eddy current signal was recorded as the measured value. The available results of the preliminary tests show that the measuring principle eddy current is suitable for the detection of filament breaks. A challenge, however, is the high standard deviation of the damaged carbon fiber, which still allows a statistically secured differentiation between damaged and undamaged areas of the carbon fiber. However, the sensor used is the first prototype, which does not yet incorporate the findings and improvements from validation on a laboratory scale and in an industrial environment. Therefore, a significant improvement is expected with each run of the Deming development cycle, so that after proof of a statistically secured detection of filament damage, the resolution and measurement sensitivity of the sensor can be addressed.


Acknowledgement: The research project ZF4558940WM9 of AiF Projekt GmbH, Berlin is funded by the Federal Ministry of Economics and Energy (BMWi) within the framework of the Central Innovation Programme for SMEs (ZIM) based on a resolution of the German Bundestag

References:
[CC18] Carbon Composites
Composites-Marktbericht 2018 – Marktentwicklungen, Trends, Ausblicke und Herausforderungen, 2018
[Ehr06]
Ehrenstein, Gottfried Wilhelm
Faserverbund-Kunststoffe. – München: Carl Hanser Verlag GmbH & Co. KG, 2006
[Mor05]
Morgan, Peter
Carbon fibers and their composites. – Boca Raton: Taylor & Francis, 2005
[Sch07]
Schürmann, Helmut
Konstruieren mit Faser-Kunststoff-Verbunden. – Berlin, Heidelberg: Springer-Verlag Berlin Heidelberg, 2007


Editor’s Note: Lukas Lechthaler is a researcher and Thomas Gries is director of the Institut für Textiltechnik of RWTH Aachen University; Richard Kupke is director of product management at SURAGUS GmbH; Dirk Feltin is CEO of Hightex Verstärkungsstrukturen GmbH; Peter Vojcena works in system development NCF Inspection at SAERTEX GmbH & Co. KG; and Christine Stamm is manager, technical service at Teijin Carbon Europe GmbH.

August 13, 2020

A Win For The Digital Twin

The supply chain digital twin is more than just a concept

TW Special Report

According to a Gartner survey, 13 per cent of organizations implementing Internet of Things (IoT) projects use digital twins, while 62 per cent are either in the process of establishing digital twin use or plan to do so. With several companies delving into the digitalization world, Claudia Jarrett, US country manager of EU Automation, explains why the supply chain digital twin is more than just a concept.

In the past, supply chains operated on strategies where manufacturers produced goods, which were pushed down the supply channel. This created gaps between supply and demand and inevitably led to poor inventory control, with instances of inventory shortage and waste.

Now, a digital version of the supply chain can be created. Involving strategically unified computing environments and technologies of industry 4.0, a digital supply chain moves assets, people and resources to where they are needed. By passing data through cloud servers and databases, the collection of information in the supply chain enhances several manufacturing practices.

For instance, manufacturers can carry out stress tests on its supply chain. Users can efficiently administer stresses and measure responses — by pairing stress parameters with response readings. A digital twin can help translate a company’s stresses into a quantified view of real consequences, such as the outcome of supplier delays.

Supply Chain Digital Twin

So, what is a supply chain digital twin? It represents a digital depiction of an organization’s actual supply chain. Its model uses prescriptive analytics, which gathers data from both descriptive and predictive sources to find the best course of action in any scenario, before applying it to the decision-making process.

Despite prescriptive models working with real data, a supply chain digital twin takes this capability further as inputs are fed into the model in real time. For instance, as a customer’s order is processed, the order and associated transactions are automatically fed into the digital twin.

To fully reflect the real world, however, other inputs that impact the supply chain are also considered. For example, if production machinery goes down or a supply shipment is late, information is sent to the digital twin through IoT devices, like sensors. Once data is collated, the digital twin determines the right corrective action and supports supply chain optimization.

Predictive Maintenance

The performance of machinery in the supply chain process is crucial. Machinery that breaks down regularly has a detrimental impact, especially when downtime needs to be avoided at all costs.

U.S.-based startup Datumix provides a virtual 3D simulation of the required equipment. It combines machine learning to develop a digital twin used to monitor the performance of equipment, before installing the algorithm in real-time. Data derived from the 3D model, coupled with artificial intelligence (AI), is then used for the maintenance of equipment.

Implementing predictive AI algorithms allows plant managers to apply predictive strategies to its supply chain. By detecting failure patterns and anomalies, learning from those patterns and then predicting future failures of machine components, manufacturers can replace equipment before it fails.

Deploying Digitalization

However, to optimize performance, the digital twin should reflect any limitations and accommodate compromises of its physical supply chain.

Modeling and prescriptive analytics are a core component of a supply chain digital twin and should involve problem-solving programming languages, such as the fifth-generation programming languages (5GL). This essential software ensures operators receive detailed insights and visibility on the supply chain, its structure and formulae to optimize the decision-making process.

For instance, Fleetpride, a U.S.-based firm that sell parts and provide services for heavy-duty trucks and trailers, built a model that uses historical shipping data to predict the shipping orders per warehouse by day, week and month. By applying decision optimization to its model, corrective action could be determined when dealing with customers, staff and even inventory placement on any given day.

In fact, Fleetpride uses prescriptive analytics to transform data and predictive solutions into real, fact-based courses of action. No longer reliant on intuition, Fleetpride utilizes advanced analytics, statistical modeling and a decision engine to solve business planning, scheduling, pricing and inventory challenges, and other businesses have the opportunity to do the same.

Internet Of Things

The idea of a digital twin isn’t new, but what is different is the concept of integrating data and inputs from the real world. IoT-connected devices are the building blocks of a digital twin, and sensor integration is key to enabling such visibility.

However, designing and integrating these sensors can be resource-intensive and time-consuming, and can even be difficult to stream data from older machines that aren’t technologically compatible. That’s why industry experts, such as obsolete parts supplier EU Automation, can supply sensors for manufacturers building a digital representation of its physical supply chain.

A digital twin is more than just a concept. Several companies are delving into the digitalization world, and although replicating what-if scenarios before physical implementation might sound like a pipe dream, digital twins are proving tangible and useful.

August 13, 2020

Innovative Partnership: More Revenue And Customer Satisfaction For Menderes Tekstil With SPGPrints’ OrtaScreen™

TW Special Report

As the biggest vertically fully integrated Textile Factory in Europe, Menderes Tekstil is an important customer for SPGPrints. However, the partnership between Menderes Tekstil and SPGPrints goes further than company and customer, as both companies aim for innovation in rotary screen printing together. An open mind and willingness to try new things are important for this progressiveness. This is why Menderes Tekstil started to use our OrtaScreen™.

Menderes Tekstil – Reliable Partner In Rotary Screen Printing

Founded in 1983, Menderes Tekstil has more than 30 years of experience in textile printing. The company is world leader in home textile and approved supplier of home textile products to giants in the European market: mainly printed and dyed bed linen and shirting. Menderes Tekstil is always eager for innovations in printing. That is why they value their partnership with SPGPrints. This is mutual. With a partner like Menderes Tekstil, SPGPrints always has the opportunity to test new products and technologies. This also applies to the OrtaScreen.

Introduction of the OrtaScreen™

Ever since SPGrints invented rotary mesh screens in 1963, they are reinventing the screens over and over to always take the printing quality to a higher level.

(left to right): Albrecht Gebhard, Tamer Poyraz, Necdet Can (standing) and Ali Uğur Köseoğlu

Designs often make use of halftones and grids, which are based on an orthogonal orientation. Printing these designs with the common rotary screens can generate undesired moiré. Due to the reinvented mesh structure of the OrtaScreen moiré can be eliminated.

The orthogonal orientation of the holes brings 4 bridges together instead of the 3 in hexagonal screens. The OrtaScreen features a 3D surface structure, allowing the paste of adjacent holes to flow together and to cover the textile substrate easily. It allows to print geometrical and halftone designs with high edge sharpness and leads to unrivaled print definition. Furthermore blotch printing is taken to a new level. This is the best available technology to get most difficult designs with highest quality.

The Positive Impact Of OrtaScreen™

Menderes Tekstil has been using the new OrtaScreen for a while now. This screen replaced the previously used NovaScreen® for a substantial part. The difference between both types of screens is especially visible in the printed halftones and geometrics. OrtaScreen helps Menderes Tekstil to print these challenging designs. Printing these designs with an OrtaScreen results in higher image definition, smoother halftones and extreme even blotches. “This high-level printing quality reflects the highest standards,” explained Yusuf Güngör, Manager Engraving & Design at Menderes Tekstil.

“We greatly benefit from the usage of OrtaScreen. Printing geometric designs, halftones and blotches with this new invented screen gives a much better quality which positively impacts our turnover and customer satisfaction,” Güngör said.

(left to right): Ali Uğur Köseoğlu, Turhan Avdan, Henk Masselink, Yusuf Güngör, Jos Notermans and Hakan Uzman

Fruitful Partnership

“Since the beginning of Menderes Tekstil in textile printing, we have been using the textile equipment of the best supplier. At that time, this supplier was named STORK. Nowadays it is SPGPrints,” Güngör said. For his team, the partnership with SPGPrints is paying off, especially with the new local team of SPGPrints’ Turkish Office. “This relationship and the constructive attitude of SPGPrints positively affect our turnover.” In the future, the focus of this partnership will be on even more innovations and technical support.

As mentioned earlier, Menderes Tekstil is always very helpful and eager to try new products and screens as a partner of SPGPrints. This innovativeness is characteristic for the company. Menderes Tekstil has been using the OrtaScreen ever since SPGPrints started selling it. As an innovative company, Menderes Tekstil has a clear vision for the future of textile printing. “The OrtaScreen will help us a lot to increase our revenue from our shirting fabric business,” Güngör said. “In the future, we plan to use these screens in all of our textile rotary printers.

Promising Results

“This new screen really improved our printing process and results,” answered Güngör when asked about the solutions and benefits the OrtaScreen offers Menderes Tekstil. “These results give us new possibilities regarding the future of textile printing. Moreover, the usage of OrtaScreen can provide the entire industry with strategic benefit.”

August 13, 2020

 

 

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