Development of Yarn Detection Sensor for Circular Patterned Yarn Dyeing Machine

The textile industry has undergone a radical transformation in recent years, driven by digitalization, automation, and the pursuit of sustainable production. In this transformation, electronic and computer-based sensor technologies are gaining prominence in critical areas such as production line monitoring, process control, quality assurance, and energy efficiency. This study examines the development of a yarn detection sensor for a circular machine featuring patterned yarn dyeing technology. Unlike traditional dyeing methods, this technology combines the yarn transfer process with the dye spray system, enabling direct patterning of the yarn. Only the required amount of dye molecules chemically reacts with the yarn, resulting in significant savings in water and energy consumption. The system, with 36 independent dyeing stations, offers flexible production; however, yarn breaks, resulting from factors such as yarn raw material, strength, twist, and friction, lead to production losses and defective package formation. The import of currently used yarn detection sensors poses a significant disadvantage in terms of cost and lead time. Therefore, this study has developed a domestically produced sensor that can instantly detect yarn breaks, communicate with the machine in real time, and automatically stop the station. The developed system will minimize production losses and delivery delays, saving energy and resources. Consequently, the design and integration of a domestic yarn detection sensor will not only improve production quality and efficiency, but will also contribute to reducing external dependency and promoting environmental sustainability. In this respect, the study can contribute to advancements in smart production technologies in the textile industry.