On-line detection of defects in fibrous members

An on-line defect detection process comprising:

• (a) producing a continuous elongated fibrous member in a fiber forming machine;
• (b) passing said fibrous member through a defect detection zone, wherein said passing includes contacting substantially opposite sides of said fibrous member with first and second fiber contacting members, wherein variations in the width of said fibrous member causes shifting of said second fiber contacting member relative to said first fiber contacting member, and wherein said first fiber contacting member is fixed to a support member;
• (c) sensing the shifting of said second fiber contacting member relative to said first fiber contacting member, wherein said sensing is performed with a sensor coupled to said support member and wherein said sensor is spaced from and does not contact said second fiber contacting member;
• and
• (d) generating an electronic signal based on the sensed shifting of step (c).

A multi-fiber article production system comprising:

• a fiber source;
• at least one spinning machine configured to form at least a portion of said fiber source into a tow;
• a tow combining machine configured to combine a plurality of said tows into a tow band,
• a support member;
• a first tow contacting member fixed to said support member;
• a second tow contacting member, wherein said second tow contacting member is shiftable relative to said first tow contacting member;
• a defect detection zone defined between at least a portion of said first and second tow contacting members, wherein said defect detection zone is configured to receive at least a portion of said tow in a manner such that said tow contacts said first and second tow contacting members in said defect detection zone;
• and
• a sensor configured to (i) sense movement of said second tow contacting member and (ii) generate an electronic signal based on the sensed movement of said second tow contacting member, wherein said sensor is coupled to said support member and wherein said sensor is spaced from and does not contact said second tow contacting member.