Design and development of yarn abrasion resistance tester

Textile technology

The present project, titled “Design and Development of Yarn Abrasion Resistance Tester”, focuses on the development of a compact, cost-effective, and automated system for evaluating the abrasion resistance of yarn under controlled laboratory conditions. Abrasion resistance is a critical mechanical property that significantly influences the durability, performance, and service life of yarns in textile applications such as weaving, knitting, and finishing. Conventional abrasion testing machines are often expensive, bulky, and lack real-time monitoring capabilities, making them less accessible for academic institutions and small-scale industries. To address these limitations, the proposed system integrates mechanical design with embedded electronics to create an efficient and user-friendly testing device. The system employs a 60 RPM DC gear motor to rotate an emery sheet-covered shaft, which generates controlled abrasion on the yarn specimen. The yarn is held under constant tension between two supports, ensuring uniform testing conditions. An ESP8266 microcontroller serves as the central control unit, enabling real-time monitoring, data processing, and system automation. A limit switch mechanism is incorporated for automatic yarn break detection. Upon yarn failure, the system immediately stops the motor using a relay control, ensuring precise measurement of critical parameters such as time to break, number of abrasion cycles, and total abrasion distance. These parameters are displayed on a 16×2 LCD interface, providing clear and instant feedback to the user. The developed system offers several advantages, including low cost, portability, automation, improved accuracy, and reduced human intervention. The prototype demonstrates reliable performance and consistent results, making it highly suitable for educational institutions, research laboratories, and small-scale textile industries. This project contributes to the advancement of smart textile testing equipment by providing an accessible and efficient solution for evaluating yarn abrasion resistance.

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