I. Assessing Abnormal Operational Status
1. Abnormal Noise and Vibration: Severe, unusual noise or abnormal machine body vibration during operation likely indicates issues such as worn transmission components or jammed rollers.
2. Emergency Stop Triggering: Automatic emergency shutdown without manual intervention, or failure to cut power after pressing the emergency stop button, indicates an electrical control fault.
3. Leakage and Smoke: Significant leakage of dye liquor or smoke emitting from the electrical control cabinet indicates a serious fault requiring immediate shutdown and inspection.
4. Roller Jamming: Stuttering fabric movement or failure to alternate winding correctly likely indicates issues such as yarn ends wrapping around rollers or a broken drive chain.
II. Assessing Dyeing Quality Defects
1. Localized Color Irregularities: Issues such as overlap marks, shade variations between fabric ends (head-to-tail shading), edge-to-center shading, color bands, or blotchiness-provided process parameter settings are correct-indicate equipment malfunction.
2. Weft-Direction Color Difference: Color discrepancies across the fabric width (left-center-right) indicate piping layout faults, such as inconsistent flow rates at drainage outlets or inlet/outlet flows directed straight at the fabric.
3. Physical Fabric Defects: Physical irregularities such as straight longitudinal creases, "annual ring" marks (loose winding marks), or skewed weft-provided the greige fabric itself is not at fault-indicate issues with tension control or roller leveling.
4. Color Difference Between Batches: Significant color differences between fabric batches processed under identical conditions indicate instability or faults in the temperature control or dye liquor circulation systems.
III. Assessing Process Parameter Alignment
1. Temperature Deviation: A difference of more than 5°C between the temperature displayed by the control system and the actual dye liquor temperature indicates a fault in the temperature sensor or heating unit.
2. Abnormal tension: If tension fluctuates by more than 10% during the operation of a fabric batch-resulting in fabric sagging or excessive stretching and thinning-it indicates a fault in the tension control system.
3. Abnormal flow rate: If the circulating flow rate within the dye vat is significantly lower than the set value during the operation of the dye liquor circulation pump, it indicates a blockage or insufficient power in the circulation pump or piping.
4. Failure of fabric edge alignment: For models equipped with an automatic edge-aligning mechanism, frequent uneven winding of fabric edges during operation indicates a fault in the edge-sensing sensor or the edge-aligning actuator.
