I. Fabric Quality Problems
1. Color Difference
Phenomenon: Inconsistent color depth in the fabric, including differences in color intensity between the edges and center, left and right, front and back, or the front and back.
Causes: Inconsistent dye liquor absorption during padding, uneven pre-drying or baking, deformation of the roller shaft, differences in dye properties, etc.
Solutions: Improve the uniformity of fabric drying, use uniform padding, and select appropriate dyes.
2. Color Spots
Phenomenon: Irregularly appearing small, dark-colored spots on the fabric, mostly occurring on light-colored fabrics.
Causes: Inappropriate dye selection, large particle size, agglomeration.
Solutions: Select suitable dyes and ensure complete dye dissolution.
3. Rope Marks
Phenomenon: Irregular wrinkles of varying shades of color appear along the length of the fabric after rope dyeing.
Causes: Insufficient or incomplete pre-setting of fabric, malfunction of the dyeing rollers, rapid heating or cooling, insufficient dyeing liquor ratio, fabric knotting in the dyeing vat.
Solutions: Ensure adequate pre-setting of fabric, check the function of the dyeing rollers, control the heating and cooling rates, adjust the dyeing liquor ratio, and prevent fabric knotting.
II. Mechanical and Electrical Faults
1. Excessive Machine Noise
Causes: Worn gears or lack of lubrication.
Solutions: Check gear condition and add lubricating oil.
2. Machine Vibration
Causes: Loose or misaligned couplings.
Solutions: Check coupling condition and realign.
3. Machine Overheating
Causes: Overload operation.
Solutions: Reduce operating speed and clean heat sinks.
4. Abnormal Indicator Lights
Symptoms: Red light (broken warp), green light (broken weft), yellow light (missing weft), white light (electrical fault).
Solutions: Troubleshoot according to the codes.
III. Operational Issues
1. Improper Shedding Amount
Impact: Too much shedding can cause warp breakage; too little can affect weft insertion.
Solution: Adjust the shedding amount according to the fabric type.
2. Improper Shedding Time
Impact: Too early will cause weft shrinkage; too late will cause fabric tearing.
Solution: Adjust the shedding time to the appropriate position.
3. Yarn Breakage
Cause: Poor yarn quality or uneven tension.
Solution: Replace with high-quality yarn and adjust the tension.
4. Knitting Misalignment or Unevenness
Cause: Needle position misalignment or uneven tension.
Solution: Correct the needle position and adjust the tension.
