In order to help customers to regulate the tension when working cotton yarns, particularly for denim and applications that require coarse gauges, Karl Mayer Group, Obertshausen/Germany, offers the Disctens model. This high-precision, electromagnetic, disc-type yarn tensioner is suitable for many applications, especially when used in tandem with the Karl Mayer Ball Warper. The new ISO Cotton direct warping machine also provides optimum benefits when used with the Disctens.
The yarn tensioner is suitable for processing yarns with a wide range of gauges. Its reliable gauge range is 30% larger than that of comparable models. It can work cotton yarns with counts of 4 to 100 Ne at the necessary tensions without any problems at all. Its tension range runs from 3 cN to 95 cN. To ensure maximum flexibility, it uses a pair of discs and the force of electromagnetic attraction. When a magnetic field is generated, the gap between the discs becomes smaller and the yarn tension increases. During this process, the magnetic force – and thus the yarn tension – is regulated digitally with a high level of precision. This is done for all package positions. Each thread of the creel is controlled by one Disctens.
The discs are driven in the let-off direction of the yarn by a motor and arranged vertically. This means that any dirt can simply fall to the ground. An optical sensor is used to check that the threads are present and moving correctly and triggers an automatic stop if these 2 requirements are no longer being met. For materials that are particularly prone to linting, the system can be fitted with an optional, built-in blower nozzle.
The Disctens can be used on all Karl Mayer GH-series creel types. It is fully integrated into the company’s PLC architecture and the operator interface used on its warp preparation systems. No additional displays or data input are required. In addition, the display also outputs all the information required. The proven opto-electronic Stop-Motion-Sensors ensure that yarn breaks are detected quickly and reliably.