ASPEX INCORPORATED :: SpinTrak , Spinnerette Inspection System




	The computerized Spintrak spinnerette inspection system operates using the principle of Video Image Analysis, and is thus more accurate, much faster, and far less costly to use than visual, oil, or airflow type inspection systems. It also eliminates any need for post-inspection cleaning, and it has no consumables. It is far more accurate than any other system, provides far more useful data, and is far less prone to human error. It will provide measurements for each and every capillary individually, as well as for the entire spinnerette as a unit, allowing for valuable analysis of the test results and testing "what-if" scenarios.

	Because the SpinTrak system has both front and back lighting systems, it can inspect not only for dirty, plugged, out-of-round, or occluded capillaries, but also for edge wear and damage. All lights are long-life LED's, which eliminates bulb replacement. Co-axial lighting is also available, should the spinnerette surface be highly reflective.

	Inspection speeds vary with the SpinTrak model and with the size and type of spinnerettes and capillaries being inspected, as well as with the distance between capillaries, but SpinTraks typically operate at about twice the speed of other video systems and four times the speed of flow systems. Because SpinTrak is a non-contact system, it also greatly reduces spinnerette handling and the subsequent possibility of damaging delicate spinnerette surfaces.

	Only the SpinTrak system has the ability to learn new capillary patterns automatically, without requiring any special programming or service by company technicians. This makes the introduction of new spinnerette designs much easier and faster.

	SpinTrak system models are available with varying sizes of inspection area and speeds. The selection between models is generally made based on the spinnerette size and the throughput requirements. Inspection area sizes ranges from 250 mm x 250 mm (10” x 10”) up to 500 mm x 5800 mm. (20” x 228”).

	This list notes some of the many outstanding features of the SpinTrak system, and will allow you to easily compare SpinTrak benefits against any other inspection system.

	Available Automatic Capillary Measurements
	Area Minimum diameter Maximum diameter Perimeter Profile (roundness) Lobe length Lobe width Inner diameters Overall diameters Any point-to-point cross-section Capillary depth (may require additional fixture)

	Speed :
	Back light inspection (for blockages) as fast as 0.35 seconds per capillary Front light inspection (for wear) at up to 0.40 seconds per capillary Additional for sub-capillary measurement 0.10-1.0 seconds per capillary Depth inspection at <5.0 seconds per capillary
	Inspectable Capillary Specifications
	Sizes 0.020 to 5.0 mm Any shape Up to 4 capillaries of the same shape per counterbore Length/diameter ratios from 0.1:1 to 25:1
	Inspectable Spinnerette Specifications
	Round: Diameters from 10mm up to 500mm Rectangular: Up to 500mm x 5800mm Weight up to >500 kg. Unlimited number of capillaries/ counterbores Any shape capillary, including multi-lobal and multi-ocular
	Spinnerette Learning
	Automatic scanning to find capillary locations and sizes, or Can Import CNC drilling files to specify locations
	Data Analysis Features
	Color-coded pictorial reports of area, minimum & maximum diameter, profile, perimeter, and wear measurement data Graphic representations of all of the above Data export to other Windows applications Capillary location analysis Statistical summaries Side-by-side comparisons between any two inspections Software enables "what-if" scenarios
	Other SpinTrak Features
	Automatic recalibration before every inspection User-controlled settings for pass/ fail criteria Monitor shows capillary enlarged 200-500 times, for review LED lighting systems eliminate bulb failures and burned optic cables Second (back-up) hard drive for system data storage redundancy Automatic focusing correction for warped or misshapen spinnerettes Tracks intentionally plugged capillaries, alerts operator when preset limit is exceeded Uses Windows operating software running on industry standard PC hardware Networking capability to your LAN Extensive report generation, including compliance to specifications report Two Security access levels Automatic air purge removes debris, cleaning beads, etc. (optional on some systems) Capillary illuminator facilitates manual cleaning/ plugging (optional on some systems) NIST-Standard Reticle available as an option, for ISO facilities. Automatic self-test record keeping for ISO requirements Remote diagnostics allow troubleshooting or upgrades without a service call Administrator sets automatic record-keeping parameters
	The SpinTrak system can inspect all spinnerettes commonly used in the staple, yarn, spunbond, meltblown, and hydroentanglement manufacturing processes.

	All new systems are covered by an expansive one-year warranty, and Aspex is very proud of their excellent performance record and infrequent service requirements. For subsequent upkeep, there are preventive maintenance service programs and telephone/ modem support packages available. SpinTraks routinely run for years with no downtime at all.

	There are currently SpinTrak systems operating in every major fiber-producing country around the world.

	SpinTrak is the proud recipient of several awards for excellence, among them a recognition award from DuPont for superior technology and fast cycle time.
	Simplified illustration of a SpinTrak Inspection System


	Day-to-Day SpinTrak Operations:
	The inspection process starts with the operator logging on to the inventory manager with the selected password. The operator then selects the spinnerette to be tested from the selection in memory. This will retrieve the specifications, including spinnerette style, capillary size, shape, and placement, and the tolerances to be used for the inspection. If he is an authorized system administrator, he can also set or change the specifications and test measurement tolerances. Once the inspection parameters have been selected, the spinnerette is placed on the fixture that has been custom-made to hold it in precisely the same relative position for each inspection. This should take only moments. Automatic inspection is then started with the push of a button, and no further operator assistance is required.

	If the particular spinnerette capillary pattern is being inspected for the first time, the system will start by scanning the entire spinnerette surface to create a map of all the capillary locations. This process is fully automatic, and needs to be done only once for each new design.

	With every inspection, the system will at this point automatically create a focus map of the spinnerette surface to allow the system to automatically compensate for any wear or warping of the surface or any slight misplacement of the spinnerette, and starts the inspection. During the inspection, every capillary in turn comes under the microscope, where the computer will use the image as seen by the camera to measure the total capillary area, the minimum and maximum diameters, the perimeter, and the profile (roundness) of the capillary. These results are automatically compared against the pre-selected tolerances to determine if the capillary is acceptable or not. If desired, it is possible to set the system to also automatically make other desired measurements, such as leg length on trilobal capillaries, or any other point-to-point measurement.

	During the inspection process, every capillary is inspected in turn, and not just representative or random capillaries. This ensures 100% certainty of data rather than an extrapolation. Also, the value of having measurements of each capillary rather than just the spinnerette in total allows for quicker problem diagnosis. Those systems that measure the entire spinnerette at one time are subject to potential error due to the possibility of over-large capillaries balancing out too-small capillaries to give the total spinnerette an erroneous passing grade, and allowing substandard spinnerettes into active use.

	When the entire spinnerette has been inspected, it is graded as either Pass or Fail. Statistics for the entire spinnerette are generated, including standard deviation, mean, CPK, over USL, under LSL and range. If there are multiple spinnerettes being inspected at the same time, these pass/ fail grades will be displayed for each one separately. Precise capillary data is displayed, with the failing capillary measurements highlighted in color. A graphic also appears, showing the spinnerette surface with the defective caps noted in color. This feature allows judgments to be made rapidly as to spinnerette disposition.

	A video image of every capillary is also stored to allow for later review, if desired.

	A user-selected plan for test deletion strategy is also part of the SpinTrak program. Choices are selected from a drop-down list and include saving all test results, saving just the last 10, the first and the last 10, among others. This strategy helps to conserve computer memory.

	The inspection lighting choice (front, back, or a combination of both) and the intensity of each component can be adjusted by the operator instantly, on the screen. Generally, front lighting is used for the detection of damage and wear to the spinnerette, while back lighting is used to detect blockages or occlusions in the capillary.

	As many small spinnerettes of the same type may be automatically inspected in turn as there are locations on the fixture to hold them. The number of locations possible on a fixture varies with the SpinTrak model and the size of the spinnerettes being inspected. To increase throughput, the fixture can be loaded and set to operate unsupervised after the operator has left. With large spunbond-type spinnerettes, the same technique can be used by always starting the system just before leaving, so that the results will be ready first thing in the morning, and thus save significant operator time.

	The proper SpinTrak system for your needs will be selected based on your spinnerette size and throughput needs. Every SpinTrak system includes motorized positioners on an anodized aluminum inspection table, a high-resolution camera, integral front and back LED lighting, zoom microscope, video monitor, industry-standard PC with Windows OS, SpinTrak software and dual hard drives for system redundancy, protected reticle (available with a NIST documentation option if desired), and a fixture custom-designed to hold your spinnerette(s). We will also build in your network card at no charge, to allow you to add the SpinTrak to your LAN. Larger models have an automatic air purge system for clearing capillaries as standard equipment, while on others this is an option. This feature also includes an illuminator that will greatly aid manual attempts to clean or plug a capillary, should this be found necessary. The screens used during daily operation are available in any of 10 foreign languages at no extra charge.

	Options available at extra cost include:
	Special microscopes that may be needed for unusual capillary combinations Co-axial lighting systems that may be required by reflective spinnerette surfaces Extra fixtures needed for additional sizes of spinnerettes Reticles with NIST- certified documentation Remote diagnostic ability, also allows upgrading via modem Upgrade to laser printer for high-volume sites

	Aspex has been delivering advanced imaging solutions to industry since 1978.

	Please call with your throughput needs and spinnerette details, and we will be happy to prepare a formal quotation for the SpinTrak inspection system most suited to your distinct needs.