BASICS OF ONLINE MONITORING OF MACHINE AND PROCESS PERFROMANCE AT DIFFERENT STAGES OF FABRIC PRODUCTION The machine and process

performance of the following stages of fabric production are monitored online. 1. Cone winding 2. Warping 3. Sizing 4. Weaving MODERN CONE WIDNING MACHINES The modern highly automated cone winding department is faced with ever increasing demands. Cross-wound packages with perfect winding-off qualities and long, knot free yarn lengths are required which in their size and form are adapted to the requirements of the subsequent processes. Added to this are the requirements for consistently higher quality of the wound yarn. Modern cone winding means constant optimizing of productivity while at the same time achieving the required quality. The cone winding department is therefore almost ideally suited for the on-line monitoring of quality and productivity at all production locations. In weaving the weft accumulator unwinds yarn from a large weft supply packages and then releases a precise amount to the weft insertion element of the loom. Variations in winding tensions during fibre production are totally unacceptable as the slightest change in tension on the forming yarn will change its physical and dying properties. The advent of splicing yarns means that ends may be joined in such a way that the differences from the base yarn is virtually impossible to see. This has opened the way for production of full size packages of knotless yarns being produced from part packages of what once would have been simply waste. In a spinning plant this recovery can represent substantial savings. FULL CONE MONITORS In cone winding, maintaining uniform and specified cone weight is major problem in almost all the mills. Various methods are followed to maintain the cone weight. The weight variations between cones, occurs mainly because of the variations in cop weight and also the breakage between the cops. This problem has become acute after the introduction of electronic clearers. This results in low cone winding productivity, weight complaints from the customers and increased cost of production. Hence full cone monitor has become essential to manage the above problems.

Methods 1. Indicating ring In manual cone winding machines, an attempt was made by providing ring in the cone holder. When the cone touches this ring, the winder will doff the cone. This method causes damages or strains to the cone and hence was not successful. 2. Cyclic cop replenishment Mills normally provide cone weight tolerance ranging from 10grams to 25 grams for every cone. Hence, if the cop weight is maintained within plus or minus 2 grams and the breakage rate is less than 2 per lakh meters, then the winders can follow cyclic cop replenishment method, check our cone weight after attaining the specified size and doff all the cones. If the variation between cops is high, then the winders have to spend not less than 0.5 minute for every cone by keeping all other drums idle by following winding and rewinding method. When they do not wind, after weighing, it leads to cone defects. 3. Measuring discs In this method, the yarn is passed over a measuring disc. The pulses from the disc are converted into length and thus the cone is monitored. This system has not become commercially successful because of high cost. 4. Template Some mills use templates to measure the cone size and doff the full cones. The cone size vary depending upon the climatic conditions, unwinding tension and winding tension given to the yarn. Hence, this method has also failed. AUTOMATIC DOFFER Doffing is carried out when the package reaches the pre-set meter age or diameter, which can be set from 125 mm to 300 mm maximum. Auto doffing is carried out by one or two doffers. The doffers doff the package and deposits over the conveyor It restarts the heads These doffers are moved by a motor at a speed of 24 m/min on a track.

Operation Logic

When the metreage has reached, the winding head shuts down, actuates the trolley, arrest transmitter and signal its conditions to the INSPECTOR CONTROL UNIT. The I.C instructs the trolley to move towards the head which is requesting a doff, as soon as it reaches to the head and if all the conditions are ready then I.C. sends a doffing cycle command to the trolley.

THE DOFFING CYCLE 1. Positioning of transfer tail and cutting of the yarn. 2. Opening of centre 3. Placement of roller on the moving centre to form the transfer tail. 4. Lifting of package holding arm to doffing position 5. Lifting of package 6. Tensioning of spring on the arm lifter 7. Lifting of yarn hook and scissor 8. Delivery of the tube between the centre 9. Actuation of package expulsion lever 10. Horizontal movement of the yarn hook. Total time taken per cycle is 20 seconds. In 20 seconds, the above 9 steps are carried out with respect to their timings only, but not in the same order. YARN SPLICER The splicer is designed for use in joining yarns where knots are either unacceptable or impossible because of some special characteristics of the material itself. SPLICING OPERATION 1. Yarn take-in Push the upper and lower yarn into the splicer using the yarn guide levers, and then clamp them there. 2. Cutting of the yarn ends The upper and lower yarn cutters cut the ends of the upper and lower yarn

3. Untwisting The cut yarn ends are sucked into the untwisting nosily pipe and untwisted. At this time, the yarn guide lever-R returns a little to allow a sufficient length of yarn to be twisted. 4. Splicing The yarn guide lever-R is pushed in again, and it pulls the yarn ends out of the untwisting nozzle. While the yarn ends are out they are held by the yarn holding lever, and a jet of compressed air from the splicing nozzle tangles and twists the yarn ends together to complete the splicing. ELECTRONIC YARN CLEARER Electronic yarn clearer functions either based on capacitance principle or photoelectric principle. The setting is kept depending on the yarn count and the fault is identified based on the thickness of the fault in the yarn and as well as the length of the fault. The yarn is passed through the capacitors. Whenever there is variation in the yarn thickness and also the length of the fault, the capacitance changes. This pulse is amplified and the knife is activated by the sensitivity control and the yarn is cut. The yarn passes through the light beam. Depending on the variation in the light intensity, the photosensitive device gives the signal which is amplified and the knife is activated by the sensitivity control and the yarn is cut. WARPING Warping is the process of winding warp threads on to a beam that can be used as the warpers beam in the further process of weaving. This is done with the help of a warping machine. In this process the supply packages in the form of cones or cheeses are mounted on a creel and the number of supply packages in the creel determines the number of ends in the beam. The warp ends are fed in the form of a sheet wound on a beam in which all ends are parallel to each other. Warping can be classified into direct beam warping and sectional warping. The of control systems in this process is significant and directly influences the quality like the appearance of the fabric that is finally woven in a loom. Warp specifications can be stored for different parameters that are memorized by the PLC and can also be obtained even during power failure. This PLC base control can also produce the data in a printout form. A Digital Numerical Control ensures that all beams are of the same length. It calculates the number of metres by continuously measuring the circumference of the beam. Controls in warping 1. Automatic Feed control system:

The supertronic section warper measures the take up behavior of the warp material after the first section is started and then adapts the feed automatically. The measuring system employs a high precision electronic micrometer. After a small amount of material has been wound on, the machine stops at a defined drum position. The measuring system relays the material height to the computer. The machine is then restarted and continues warping until the second measuring stop, which again takes place after only a few millimeters have been built up. The measuring operation is repeated and the computer works out the correct feed from the two measurements. 2. Automatic Tension Controller: The yarn tension while warping continuously changes during the course of the process. To regulate the tension of the yarn from the supply package, it is necessary to control the yarn tension. The required yarn tension in warp section is precisely set on electronic tension sensor meter. The set value of creel tension is continuously monitored by pressure load cells mounted on warp table. When there is loss in tension it gives a signal to the creel PLC, which in turn regulates the yarn tension very precisely so as to get perfect warping in all sections. This is the most important feature required for preparing highest quality sectional warp beams for onward sizing operation. 3. Automatic warp divider: Electronically controlled feed roller that ensures that all sections in the conical area are of the same height, thus ensuring that every end of the beam is of the same length. The lateral traverse is computed electronically. A feed roller is laid against the drum surface and its position is registered. The section is then run-on, pushing the roller back in accordance with the build-up. An electronic transmitter device divides the distance travelled into timed impulses, which are fed to the computer that calculates the rate of traverse and displays it digitally. 4. Precision Length Measuring Unit: A presser roller presses on to the circumference of the beam and senses the build in diameter of the beam. This type of presser is used in case of grey yarns. When the set value is reached the machine is automatically stopped and the beam can be removed from the warper. When dyed yarns are used, the presser roller may abrade the colour on the yarn and hence laser-sensing is used for sensing the diameter of the warp beam. The computer controlled wind-up of the beam guarantees the identity of all sectional beams of the warping set. During the warping process, the diameter of the beam is measured by a LASER system. The computer compares the current warping values with the given values of the master beam and be adjusted by alternating of the revolutions. 5. Automatic braking system:

Missing ends in the warp sheet can be avoided by using a braking system that has to function during a thread break while warping. To achieve this control a powerful air cooled DISCBRAKE on each side of drum is provided. The Hydro-pneumatic circuit present in this arrangement ensures soft but extremely effective instantaneous braking during a warp brake. In addition, a servo assisted hydro-pneumatic system helps to regulate brake pressure automatically for uniform yarn winding on to the beam that can be mounted on the loom for weaving a fabric. SIZING Sizing is a very important process to produce warps for weaving. If size application can be successfully controlled by the control system, the size application can be uniform without safety reserves. Controls in sizing are 1. Temperature control It determines the viscosity of the size paste which plays a decisive role which in turn determines the percentage of size pickup, size penetration and end breakages during weaving.
2. Size level control The electrically operated controlling device uses two electrodes

located in the size mixture. The electrode conductivity of the size paste itself provides the basis for the application of the level control system. The system maintains the size level within + or 5 mm of the desired level. 3. Tension control on single end sizing Each beam has a power brake impulse from the beam tension controller. The power brake not only deal with emergency stops but controls the creel tension by progressively reducing the braking torque as the beams are reduced in unwinding diameter. 4. Stretch control The unit consists of two special transducers and the display unit. The pulses generated by the transducers are processed by an electronic circuit and the result is digitally displayed as percent stretch. The gadget is useful as it gives the operating stretch instantaneously thus is facilitating corrective action wherever necessary.

WEAVING High speed weaving machines are equipped with precise positive monitoring devices with quick response. The electromechanical and purely mechanical components are replaced by electronic controls and monitoring devices. The automated controls used in weaving are the following.
1. Electronic shedding- Shedding is carried out by means of using servo motors.Electronic

shedding opens up completely new possibilities for producing ultra-fine,dense and delicate fabrics of a quality never before achieved. As each shaft is controlled by servo motor the movements of the shafts can be individually controlled. The crossing time and duration of standstill can be programmed easily at the terminal. 2. Automatic Pick Controller ( APC) The computer automatically sets all conditions for weft insertion according to the weaving patterns and rpm set by the automatic initial condition setting (ICS) system. Moreover, automatic adjustments are made to compensate for changes that occur afterwards. When a cheese change occurs, main pressure is momentarily increased via a bypass circuit at the main tank. With this system, not only is the wasteful consumption of air is prevented, but also weft insertion is kept stable regarding of cheese changes. APC Main is extremely effective for filament weaving operations.
3. Warp Beam Let-off with Electronic control

Saurer developed automatic warp let-off motions of the ground and pile warps, by which the two warps are let-off by drive motors. Control of these motors is performed by signals from proximity switches fitted to levers of the suspended roller; the switching cycle of the proximity switch is too small that on any slight change in the pre-selected warp tension the warp let-off motor is switched on immediately for a short time. 4. Electronic Take-up motion Weft density can be changed at will even while operation is in progress, making border weaving possible for high grade handkerchiefs, etc., All settings can be designated from the new function panel. Settings for up to 100 different patterns can be designated. Change wheel changes are unnecessary, simplifying the weaving start up operation.

Take up torque is controlled according to the diameter of take-up cloth. The result is constant cloth take-up tension. A multi-disc clutch provides stable cloth tension regardless of the diameter of the take-up cloth. 5. Electronic weft detectors On electronically controlled weaving machines the machine is no longer stopped by awkward mechanical means but when weft is absent the detector fork produces an electronic signal through a charge in the magnetic field. This is evaluated by the electronic control and the machine is stopped in the desired position. The electronic control can also switch on the automatic reverse and stop the machine in the open-shed position when a weft thread breaks. Compared with the mechanical weft detectors the reaction is appreciably quicker and adjustment and maintenance work is largely unnecessary. 6. Electronic warp stop motion The light beams are emitted in the shed by lamp, fixed at the reed, and lamp stationary mounted on the machine frame. The two light sources are operated by a magnetic switch within one part of the machine revolution as long as the shed is fully open. On the opposite side of the warp sheet, photoelectric transistors are fitted on the reed and the machine frame respectively. This warp stop motion works when a warp end breaks or when spliced warp ends pass. The luminous flux is disrupted and the weaving machine is stopped. This type of warp stop motion is suitable for the weaving widths up to 4m. It is actually a contact less checking of the shed cleanliness. The stop motion gives an outstanding reliability in the silk and filament weaving. It appears that owing to the textile dust and fly connected with the staple yarns of natural fibres as well as to the water spray connected with the water jet weaving, it will be less reliable in the above two sectors. 7. The contact less warp protector motions A weft carrier moves in the direction of screen and when it attains the exit position, the light beam emits from the lamp and is directed towards the phototransistor. Disadvantage of this system is that the stop motion fails to operate if the lamp is burnt or soiled. According to modified design, the stop motion operates through two checking positions: The screening of the light beam by the moving weft carrier between lamp and photoelectric sensor is merely registered by the stop motion and the weaving is not stopped. When the weft carrier attains the exit position, the photoelectric sensor must again be exposed to the light otherwise the weaving machine would be stopped. Both checks are

interconnected so that when a short pick occurs or when the lamp filament is burnt, the weaving machine is stopped. A capacitance warp protector motion operates on the principle of the change of the sensor capacitance caused by a metallic weft carrier attaining the exit position. 8. LOOMDATA On line monitoring system employed in a loom , which monitors performance of the loom and records the productivity of the loom as reports. The configurations of the LOOMDATA system are Machine Entry station The production sensor Concentrator Bus Feed The central unit Terminals

ELECTRONIC YARN CLEARER Electronic yarn clearer is now firmly established as yarn fault detectors in all ordinary and automatic cone winding machines. There are basically two principles namely; Capacitance type: Yarn

OSCILLATOR

FIBRE TYPE CONTROL DIELECTRIC

AMPLIFIER
SLUB SIZE DISCRIMINATOR

KNIFE ACTUATOR

SENSITIVITY CONTROL

Block Diagram of Capacitance Type Electronic Yarn Clearer The block diagram shows the principle of capacitance type electronic yarn clearer. In this type, the yarn is passed through an air-spaced measuring condenser consisting of two parallel plates with air as media. The yarn fault limits according to yarn cross-section, length and spinnerss double are set by using suitable knobs in the instrument. As the yarn passes through the capacitor , according to the length and cross section of the yarn, the capacitance value changes. This is related to the mass of the material between the plates. The condenser measures the material and electric signals are fed to an amplifier which amplifies the signals. The amplified voltage is transferred to a discriminator which measures the pre-set fault limits. If the signals exceed the limits, the signal is fed forward and through cutting impulse, a knife is actuated to cut the yarn. A fibre type di-electric and sensitivity controls are used to get the required sensitivity during the operation.

Photo-cell type: Yarn

PHOTO SENSITIVE DEVICE

LIGHT LIGHT SOURCE SOURCE

TEMPERATURE STABILISER

LIGHT COMPENSATOR

AMPLIFIER

SLUB SIZE DISCRIMINATO R SENSITIVITY CONTROL

KNIFE ACTUATOR

KNIFE ACTUATOR

Block Diagram of Photoelectric Type Electronic Yarn Clearer The block diagram shows the principle of the photo-cell type electronic yarn clearer. The yarn is passed through a light source and is scanned by the light source. Opposite to the light source, a receiver is provided to receive the light rays emitted from the light beam. The yarn faults, limits for thickness, length and spinners double are set by using suitable knobs in the instrument. As the yarn passes through the light source, the yarn is scanned by the light beam. The scanned portion interrupts the light beam which changes the signal from photocell. These signals are fed to an amplifier which amplifies the signals. The amplified voltage is transferred to a discriminator which measures the pre-set fault limits. If the signals exceed the limits, the signal is fed forward and through cutting impulse, a knife is actuated to cut the yarn.

CONTROL SYSTEMS USED IN SIZING If sensors and measuring instruments are used in the textile industry in the appropriate manner, production process becomes safer and reproducibility is improved. This increases the level of quality and productivity while reducing energy costs resulting in lower manufacturing costs for any given textile material. To obtain these objectives sensors, measuring and control devices are proposed.Sizing is a very important process to produce warps for weaving. If the size application can be successfully controlled by the control system, the size application can be uniform without safety reserves. Modern sizing machines from SUKER, MULLER, BENNIGER, ZELL, TOYOTA are having sensor controlled systems which monitor the process and operating condition and maintain at set level, so the machine can run without stoppage and uniform size will be applied. The following controls are employed in sizing Temperature control Size level control Automatic tension control on single end sizing Stretch control Size application measurement control

TEMPERATURE CONTROL It determines the viscosity of the size paste which plays a decisive role which in turn determines the following: 1. Percentage of size pickup 2. Size penetration 3. End breakages during weaving The thermostat tube is inserted into the size paste through a hole on the side of the size box. It is connected to the throttling valve by means of a capillary tube. The thermostat is equipped with a temperature setting unit which can be adjusted by means of a key at the end of the thermostat tube. The throttling valve is situated in the steam supply line. A bypass arrangement is also provided to supply the steam directly to the size box. In such cases the valves X and Y should remain closed and the valve Z should be open. When temperature of the size mixture in the size box reaches the predetermined degree, the fluid in the thermostat tube expands along the

capillary tube and closes the throttling valve which has a double set ring thus cutting off the steam supply

A: Thermostat tube B: Throttle valve C: Capillary tube

D: Sieve X, Y, Z: Valves

When the temperature falls below the preset level due to the cutting off the steam supply, the fluid in the capillary tube contracts and the spring at the top of the housing causes the valve to open and allow the steam to pass from the supply line to the size box, once more. SIZE LEVEL CONTROL

A, A: Electrodes B: Diaphragm value

D: Relay E: Size box

C: Electro-pneumatic relay

G: Strainer

The electrically operated controlling device uses two electrodes located in the size mixture. The electrode conductivity of the size paste itself provides the basis for the application of the level control system. A slight difference between the electrodes prevents the system of cyclic opening and closing of the size-flow value due to turbulence or foaming in the size box. When the size level falls below the lower electrode the circuit is broken and the electro pneumatic relay is deenergized and the air operated valve controlling the flow of the size paste is open. When the size paste level rises and reaches the upper electrode the electric circuit is closed and the relay closes the control valve. The system maintains the size level within + or 5mm of the desired level. The disadvantage of this deposition of the size material on the electrode affects the working of the control device. This problem can be overcome by coating the electrode with Teflon material. In the place of the air operated control valve a solenoid operated control can also be used. AUTOMATIC TENSION CONTROL ON SINGLE END SIZING Section Beams Loom Beam

TG TG PB PB PB PC

IM MB TG
Tension Tension Controlle Controlle r Speed Controlle r M M M M M

Tension set
Tension Controlle r

Winding Tension set

Taper Tension set

Speed set

PB- Power Brake PC Power Clutch MB Mechanical Brake

M- Motor IM Induction Motor TG Tacho generator

The headstock is designed to operate at high speed of 140-150m/min. The winding tension is also high. Each beam has a power brake impulse from the beam tension controller.the power brake not only deal with emergency stops but controls the creel tension by progressively reducing the braking torque as the beams are reduced in unwinding diameter. The draw roll in the head stock is driven through a power clutch which is imposed from a second tension controller. Both controller have independent settings and are interconnected and each separately linked to the Tacho-generator. The creel power brakes are also capable of providing tapertension or tension gradient down the weavers beam. STRETCH CONTROL BTRA has recently developed a digital stretch meter specially designed for continuous monitoring of percent stretch on sizing machines. The display unit along with the sensing units consists of two special transducers and the display unit. One of the transducers is mounted on the guide roller preceding the sow-box. The other transducer is placed on one of the rollers of the drag roller assembly at the headstock. The pulses generated by the transducers are processed by an electronic circuit and the result is digitally displayed as percent stretch. The gadget is useful as it gives the operating stretch instantaneously thus is facilitating corrective action whenever necessary. One display unit can cater to three sizing machines, while a pair of transducers is required separately for each machine. The salient features of this stretch meter are its fully solid state circuitry, high accuracy and easily readable bright red display. The construction of the unit is robust which help to withstand vibrations and hot humid conditions.

Display Unit

Transducer 1

Electronic Circuit

Transducer 2

Guide roller

Sow-Box

Headstock

Drag roller

SIZE APPLICATION MEASUREMENT CONTROL The moisture content of sized warp is measured continuously after the yarn passes through the sizing trough and before the drier without contact and free of inertia by means of microwave absorption. With constant size liquor concentration, a change in moisture content means an immediate change in the degree of sizing.

The microwave measuring heads are mounted on a stainless steel measuring frame. Since steam clouds and high temperature occur behind the sizing trough, the measuring heads are protected by a temperature controlled warm air cushion, a warm air unit producing hot air, which heats the entire measuring frame and washes round each measuring head. Measuring faults due to steam clouds are thus avoided and the measuring heads are protected against too high temperature and condensation on the measuring frame and consequently droplets on the fabric are prevented. AS measurements can be processed visually with PLC for controlling squeeze roller pressure in the sizing trough. In order to meet the special sizing requirements, special control algorithm have been developed, guaranteeing a uniform degree of sizing at any time and thus maximum weaving efficiency. Size application is affected by numerous parameters. Speed Squeeze pressure Squeeze roller hardness Liquor temperature

The effect of all of this parameters can be identified on time with the size application meter AS. Sizing can be largely uniform with consistent use of the AS 120 and size application control.
Digital Display

Sizing Trough

AS

Drier

ONLINE MONITORING DEVICES IN WEAVING 1) Electronic Controls and monitoring devices on Shuttle weaving machines The electromagnetic clutch and brake which are electronically controlled performs the following functions Switching ON and OFF Slow forward and reverse running Single pick control by push buttons For precise control and monitoring, crank angle indicators necessary. They give information to the electronic control of the machine position or give the signal at the time at which a process is to be completed. The indicators are adjustable within certain limits. In order to reduce weaver movement to the minimum, the push buttons are located at both ends of the machines on wider machines additionally in the centre. Stop buttons at the back of the weaving machine provide for stopping from these also. Three section warning lamps indicate the causes of stoppages so that they may be remedied without a lengthy search. Advantages of push button controls Permits simple positive operation Shorter training times Shorter manual work for repairing weft thread breaks Reduction in cloth faults as faulty operation is eliminated. Shuttle flight monitoring: The shuttle with attached permanent magnet passes over the left side sensor on entering the shed from the left and on leaving the shed passes over the right hand sensor. Sensor1
Left Shuttle r

Sensor 2
Right

These sensors each pass a signal to the electronic control which compares the actual time of the shuttle with the set time of the impulse transmitter attached to the main shaft. When the time does not agree ie., if the shuttle arrives at the right side sensor too easy or too late, the electromagnetic brake is actuated through electronic control and the weaving machine is stopped.

Electronic Monitoring devices on Rapier weaving machines Electronics are used on rapier machines primarily for weft monitoring. For rapier weaving machines operating on the Dewas system (tip transfer), the piezoelectric monitoring system is used for preference. The weft thread without any additional tensioning is passed at low angle over the sensing unit. The start duration of monitoring are determined by the control system. The Loepfe system consists of a stationary coil and a switching quadrant rotating with the weaving machine crankshaft. A signal is thus produced by induction. Eltex uses a light cell for control which operates in conjunction with a marker on the crankshaft as an electronic switch. On electronic weft detectors for rapier weaving machines have shown that the required minimum speeds for the positive functioning of the device on the Dewas weft insertion system is dependent upon the following criteria.
1) The warp-round angle of the weft thread

2) The thread material 3) The yarn count and 4) The potentiometer setting It was demonstrated that a certain pressure must be exerted on thread guide eye or the warpround pin for the weft detector to be able to register any thread movement. The following advantages of electronic compared with mechanical weft yarn detectors may be quoted Monitoring of weft yarns of all types over the full working width No movable sensing parts Simple mounting, adjustment and maintenance Monitoring of single, double and multiple weft insertion, and Low thread tension and no weft thread breaks in the centre of the cloth Real time monitoring and planning for weave room Real time machine monitoring and production reporting is still one of the primary functions of a CIM system for a textile plant. Weave Master is a loom monitoring system. Through a Graphical User Interface(GUI), Weave master users are constantly informed about the actual situation in the weave room resulting in faster reactions to problems and an increased efficiency. Powerful analysis tools allows quick identification of poor performing machines and bottlenecks in planning, resulting in an optimal usage of production capacities. With todays small order quantities and short delivery times, scheduling has become a critical function for the textile mill. Weave Master offers the planning department an interactive tool allowing them to optimize loom

loading based on real time information. Using the World Wide Web, the salesman can give immediate and correct information about deliveries. Color Mill: The most important real time analysis tool of the Weave Master is the Color Mill. On this colour coded lay-out of the mill, the machines are pictured in a number of colour, each colour indicating a certain machine status or alarm condition. From a data selection window, the user selects the type of information to be displayed: efficiency, speeds, stop rates etc., For each data item, exception limits can be defined and problem machines are automatically flagged. User definable filter sets allow the user to display only these machines which correspond with a certain condition, for example all machines with an efficiency less than 85%, all machines waiting for an intervention, all machines weaving a specific style etc., A mouse click on a specific machine opens a window with a detailed report showing all required information for the selected machines. As a unique feature within Weave Master, these detail reports may contain any user defined mixture of text and graphics. Cockpit view: The Cockpit view is the ultimate analysis tool for the plant manager and the industrial engineer. Four graphs show the vital information needed to take quick decisions at the glance of just one screen. Film Report: The film report is the result of an automatic machine activity sampling carried out by Weave master. Based on user definable time intervals, the film report makes a complete machine diagonistic and shows whether efficiency loses were due to one long stop or were caused by several short stops. Electronic yarn tension control: An additional tension meter allows you to quickly measure weft tensions accurately. The portable and precise sensor is connected to the microprocessor of the machine. The tension values are displayed as a graph, so that operator obtains the information needed to fine-tune and control setting very fast. Fine-tuning and troubleshooting is easy thanks to the immediate feedback. The results are repeatable and reproducible on other machines. Using the tension meter will have a direct impact on productivity and quality. Each prewinder can be equipped with a new type of Programmable Filling Tensioner (PFT). This PFT is microprocessor-controlled and ensures optimum yarn tension during complete insertion cycle. Reducing the basic tension is an important advantage when picking up weak yarns, while adding tension is an advantage at transfer of the yarns and avoids the formation of loops. The tension control enables you to weave strong or weak yarns at even higher speeds. It also drastically

reduces the amount of filling stops, and enables you to set an individual waste length per channel and reduce the waste length for some channels.

LOOM DATA The continuous supervision of the efficiency of all machines provides for immediate determination of weaknesses which can then be corrected. A subdivision of down-times with respect to short stops and longer out of the production times provides directives for instituting systematic increase in machine output. Lower stop frequencies The automated and continuous control of the stop frequencies at each single machine makes possible and immediate detection of outsider conditions, which can then be corrected. Many comparison possibilities between separate machines and any number of selected machine groups facilitate the determination of improved operating conditions and a means of reducing stop frequencies step by step. Improved Cloth Quality Every mahine stop, very correction at the machine and every start position is a reason for a cloth fault. A reduction of the stop frequency which can be achieved with the USA loomdata which also represents a reduced amount of control at cloth inspection and lower of second quality fabrics. Purpose oriented use of Personnel The activity of the over looker and the maintenance personnel is concentrated correcting weakeness in the production process. The success of the measures undertaken checked by those responsible in a simple manner. Increased production speeds Up to- date information with respect to style-specific running conditions is the important prerequisite for an increased pick entry rate. The automatic nominalized comparison of the speeds of all machines immediately indicates any deviations with machines. Simplified Production Planning Reliable mean values with reference to style-specific machine outputs and the determination of production improvements facilitate production planning. Special reports the necessary survey with respect to warps on stock and the warp-out prediction at the weaving machines. Applications Quick achievement of optimum operating conditions after a style change Purpose oriented application of maintenance personnel instead of routine control maintenance work.

Adaptation of the machine allocations per weaver to actual workload conditions. Shorter running in-times for newly installed weaving machines and therefore an earlier use of capital-intensive machinery. Avoidance of production losses as a result of missing warps or due to an unexpected concentration of warp change-over. Tracing out of long trends and achieved improvements by means of a simple graphical representation of the more important characteristic data. Reduction in the number of styles by determining those styles which are being produced under uneconomic conditions. Reduction of the warps on stack with the corresponding cost savings by means of an improved survey and more accurate planning of warp manufacture Discontinuation of the reading of pick clocks and the manual methods of production control Discontinuation of routine stop checks Determination of optimum operating conditions with respect to humidity and temperature effects, the yarn material being applied , warp preparation, machine settings etc., Further processing of the automatically determined production planning, calculations, bonus systems, material control etc via a central computer system.

Configuration of loomdata
Machine entry station Production sensor Concentrator

Bus Feed

Central Unit Terminals

Machine entry station monitors the important production datas such as efficiency etc., Production sensor: The sensor determines the speed of a shaft which is rotating in proportion to the production. From the revolving impulses, the following information is available via the weaving machine: Running/stop Efficiency in percentage Number, frequency and average duration of the shorts stops Out of production times Production speed Production amount

The production sensor has been arranged for the special ambient conditions encountered in textile mills. The signal determination is undertaken by means of an inductive sensor and is therefore not influenced by dust or dirt. The built-in light emitting diode signalizes the revolving impulses and provides for a simple function control directly at the weaving machine.

Concentrator- The data are temporarily stored in the concentrator Bus feed It provides central current supply for the detection system The Central Unit The central unit is the heart of the LOOMDATA computer controlled data system. It fulfills primarily the following functions: Periodic calling up of the concentrators and machine stations Continuous preparation and memorizing of the machine signals. Control of the dialogue with the user via the monitor and printer. Output of reports Output of pre-ordered data via the special on-line interface for further processing on and central computer system

Control of the program timings via a built-in timer Determination of the allocation and control entire

The central unit is arranged according to the special requirements of a process data system applied to weaving:

The central unit is fully electronic and requires no special climatic conditions. It contains neither parts which are sensitive to dust nor to wear such as ventilators, disc drives, etc., The program cannot become lost as it is contained in fixed value memories (EPROMS)

Terminals This gives the most important production data as summarized reports known as standard reports.

COMPUTER APPLICATI0NS IN WET PROCESSING The first requirement in process control in textiles is to monitor the variable following parameters 1) Temperature of the liquor 2) Flow rate 3) Level of Liquor and concentration 4) Pressure and PH value The above parameters are controlled by 1) Electronically controlled valves 2) Motor drives 3) Pumps 4) Heating elements 5) Microprocessor based equipments Functional diagram of process control system
Wet Processing unit

Raw material quality

Temperature

Pressure

Flow

Speed

Product quality

Computer

In a wet processing unit the raw material which is fed is monitored and its datas are stored in the computer. The process parameters like temperature, pressure, flow and speed are monitored and controlled accordingly to get better productivity which can be tested in the final product.

Microprocessor based chemical dosing system Level sensor

Alkali

Level sensor
Dye

Level sensor
Salt

Temperature sensor

Microprocessor

Keyboard

Steam supply
Display Printer

Microprocessor based system to control various operation. The input details are fed into the microprocessor control through the keyboard. The microprocessor with the software works and controls the various operations in the dyeing unit. The hardware system involved here is 1) Micro computer unit 2) Various tanks 3) Motorized valves 4) Temperature and level sensors 5) Alarm which activates if anything goes beyond the set limits. Water consumption control system This system measures the rate of fabric being processed and calculates the volume of water. It actuates the appropriate motorized control valve. If the water is full in the tank, the system ensures to stop valves to stop the water flow. Conductivity and turbidity sensors are also utilized to sense the level of the water while washing.

Fabric Water Overloading tank

Water control system

Wet on-wet control system Microprocessor based instrument system can be utilized for better mercerization by monitoring and controlling following parameters 1) Concentration of caustic solution (280g/l) 2) Liquor temperature which influences viscosity 3) Penetration time (35-50 sec,10-20C for cold mercerization and 25-35 sec,60-80C for hot mercerization) 4) Tension of material Computer Colour Matching Colour matching is the art of reproducing the exact shade. Computer colour matching is the science of predicting the recipe or the formula for exact shade reproduction.Visual colour matching is subjective method whereas colour matching using Spectrophotometer is Objective colour matching. This works under the optical principle. When two samples match, their tristimulus value are identical . ie., X1=X2 Y1= Y2 Z1 = Z2 Where X, Y, and Z are the tristimulus values of coloured materials 1 and 2

Usually when light is distributed from the source, the spectral power distribution of source is the X value determined from the graph as

400 (nm)

700

where X= K PR x

Y is the spectral reflectance of object and Z is reflectance of the observer which are shown in the following graphs.

400 (nm)

700

400 (nm)

700

where X= K PR z Colour mixing law Colour mixing law is of three types 1. Additive colour mixing

where X= K PR y

2. Subtractive colour mixing 3. Complex Subtractive mixing Complex subtractive mixing: When energy is removed from the incident beam by the process of absorption and scattering. Kubleka munk law is used to predict the colours obtained by complex subtractive colour mixing As per Kubleka munk function Reflectance Concentration of solution

F(R)

Concentration % Spectrophotometer is used to measure the reflectance value

Flowchart of Computer colour matching Input Reflectance value of and X, Y, Z standards

Choose three dyes from the datalist Calculate dye concentrations C1, C2, C3

Negative Concentration outside tolerance limit

NO

Yes

Compute X,Y,Z values for three dyes

Calculate and compare with standards

Yes

No

Calculate cost of dyeing

Yes Print out Print out

NO

Computer Colour Matching for fabric

Customer Sample

Analyse Reflectance value by spectrophotometer

Recipe suggested from computer data(C1,C2, C3)

Yes Production department

No

TEXTILE CAD Technology is radically changing the relationship between the designer and the finished product. As the work that occupies the space between the designer and consumer is now capable of being totally automated, job functions, job descriptions and the entire product development and production process are changing. Software simplify and streamline the endless repetition that go into producing designs, revising size specifications, costing, infact the entire product development process. Textile CAD refers to products for Fabric Design. The software is not only meant to assist you in design but also for further implementation to different production procedures. Apart from the vast array of facilities, the three main applications of any of our products are 1. Research and Development of Design and Fabric 2. Production Planning and Implementation 3. Presentation for Marketing and sales Design creation softwares Some of the design creation software used are Adobe Photoshop Adobe Illustrator Corel draw Photo Paint Micrografx picture publisher MS paint etc.,

Software Companies Textronics Wonder Weaves System Dream weavers TDS Jacquard

Software Development

Mostly VB, ASPL(Advanced Software Programming Language) are used for developing softwares. CAD/CAM/CIM

Features of designing softwares 1. Colour mode- A colour mode determines the colour model used to display and print images. Photoshop bases its colour modes on established models for describing and reproducing colours. Common modes include HSD, RGB, CMYK.
2. Layout of designs- Layout determines the height and width of the designs to be

created. These layouts vary for different end uses. Approximately one pixel is determined as one thread for Textile purpose. Therefore for Jacquard design creation, initial layout creation varies according to the hook capacity of the Jacquard. 3. Design creation using Tools Tools in a software are the basic elements for creating a design. Tools vary from package to package but their aim is to create a design effectively with less effort. The tools are classified as Vector tools and bitmap design creation tools which are further classified as design creating and design editing tools. Ex. The move tool, The lasso tool, magic tool, crop tool. 4. Vector based designs Vector designs are made up of lines and curves defined by mathematical objects called vectors. Vectors describe an image according to its geometric characteristics. 5. Transformation of designs- Operations like to scale, rotate, skew, distort or apply are the transformations performed in the design. Scanning of fabrics and art works A scanner captures images from fabrics, prints, poster, magazine pages and similar sources of computers editing and display. Very high resolution scanner are used for scanning for high resolution printers. Scanner usually come with Adobes Photoshop product. GARMENT CAD Richpeace Garment CAD system product series is of three types 1. Pattern design system (PDS)

2. Garment Grading System (GGS) 3. Garment Marking System (GMS) Pattern Design System (PDS) It has powerful and abundant pattern design tools. Free modifications and precise measurements Auto magnetic sizing enable you to locate each point accurately. Easy Darts shift Pieces overturn Copy Mirror Spread Modify Rotate

This system can be connected with scanner, plotter and printer. PDS

Free Design Free Design:

Formula Design

It is easy to make the frame of your pattern in Richpeace. There are many professional design tools which can help you draw and adjust your designs easily. It can help you draw the corner of the pockets easily, merge darts. Curves can be adjusted or merged. The pattern can be rotated. Formula draw:
1. The system can record all formularies and measurements of each step in your design. So

that one can revise their design by one mouse click of the right button.

2. Specifically, one can change the measure of each body part easily or create new size

easily by editing the measure and size again(Auto grading) 3. Intelligent: when one piece is adjusted, the other pieces related to it will be adjusted . For example.when the armhole curve is adjusted, the sleeve will move together automatically. Garment Grading System (GGS) Providing point grading, line grading, regular grading and body grading. Editing the pattern input through digitizer. Various and sufficient options for points, lines, curves, darts, pleats, notches and shirring. There are also many modifications tools False sewing, adding pleat, segment duplication, spreading etc., wonder scale zooming and auto shrinking. Easily connect with pattern design system and garment marking system and also can connect with different Input/ output equipments, such as digitizer, plotter and printer. Garment Marking System (GMS) Fully automatic and interactive marking methods. Multiple option settings enhance efficiency. This system can give efficient marker. It can provide localizers with which patches can be removed or rotated. The whole marker can be viewed and much more details can be obtained. The plotter or printer can be used for outputting different scale marker. Richpeace Garment CAD can connect with most of the popular plotter, digitizer, printer, cutter, scanner etc., Usually, if one make patterns by themselves, a plotter is enough. If the patterns are completed by others and you want to use the computer to get the different sizes and arrange the marker, then you need a digitizer and plotter. Richpeace Digitizer Overview- Richpeace digitizer is vey useful in all kinds of digital area, ie., Garment Industry. Fashion Designing, Mapping, Mining, Punching and Environment Protection. It allows savings most standard settings for more than 30 kinds of software in the option parameters set up and supports about 30 kinds of digital formats. It is friendly, compatible and easy to connect with most popular graphic applications ie., AutoCAD, Mapgis, Citystar, Mapinfo, Arcinfo, Microstation, Supermap, Openinfo, Optitex, Arise, Billy, Cyber, GmCAD, Genemap, ViewGIS etc., Standard features 1. Hardware interface Rs-232 serial Interface 2. Baud rate upto 19,200

3. Output rate up to 100 pps 4. Technology Electromagnetic 5. Power Requirements 220V 10% ,50Hz Richpeace Plotter Richpeace plotter which is supported by a wide range of popular CAD software, plots efficiency on Textile papers, including Heat Seal and Brown paper of various widths from 1000mm up to 2000nm. The compact and reliable system works over unlimited length and provides a wide selection of pen types ie., standard fibre tip plotter pen. LECTRA This the latest software used in Garment designing and following are the different modules used. 1. Modaris- This is used for pattern making 2. Dlamino This is used for marker planning 3. Kalideo weave This is used for Woven fabric 4. Kalideo Knit This is used for knitted fabric 5. Kalideo Print - This is used for Printing and designing.