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Development of Yarn Detection Sensor for Circular Patterned Yarn Dyeing Machine

Neslihan Okyay1✉,
Fatih Işık2,
Necip Fazıl Ateş3,
Sümeyye Kes4
1Karacasu Tekstil R&D Department, Kahramanmaraş ,Turkey
2Karacasu Tekstil R&D Department, Kahramanmaraş ,Turkey
3Karacasu Tekstil R&D Department, Kahramanmaraş ,Turkey
4Karacasu Tekstil R&D Department, Kahramanmaraş ,Turkey
Received:Oct 15, 2025→Accepted:Nov 22, 2025→Published:November 29, 2025
DOI: 10.56038/ejrnd.v5i1.688
Vol. 5, No. 1
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A domestically produced yarn detection sensor was developed to instantly detect yarn breaks and improve production efficiency in circular patterned yarn dyeing machines.

The textile industry is undergoing a transformation with digitalization and automation. A yarn detection sensor was created to minimize production losses and delivery delays in circular patterned yarn dyeing machines. The sensor can detect yarn breaks and communicate with the machine in real time, automatically stopping the station to prevent further losses and promote environmental sustainability.

Abstract

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.
Keywords
Yarn break sensorsPatterned circular dyeing technologySmart Production and Automation in Textiles

References

  1. 1.Wang, Q, Huang, R, Lu, C, Pan, W, (2017), Yarn break detection using an optical method in real time, Journal of Optical Technology, Vol. 84, No. 5.
  2. 2.Sparavigna, A, Broglia,E, Lugli, S, (2004), Beyond capacitive systems with optical measurements for yarn evenness evaluation, Mechatronics 14, 1183–1196.
  3. 3.M. P. Millman, M. Acar, and M. R. Jackson, (2001), Computer vision for textured yarn interlace (nip) measurements at high speeds, Mechatronics 11, 1025–1038
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Cite This Article
Okyay, N., Işık, F., Ateş, N. F., Kes, S. (2025). Development of Yarn Detection Sensor for Circular Patterned Yarn Dyeing Machine. *The European Journal of Research and Development*, 5(1), 276-280. https://doi.org/10.56038/ejrnd.v5i1.688

Bibliographic Info

JournalThe European Journal of Research and Development
Volume5
Issue1
Pages276–280
PublishedNovember 29, 2025
eISSN2822-2296

Indexing & License

Open AccessCC BY 4.0CrossRef DOIORCIDOAI-PMH

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