Control Systems in Textile Machines
By G. Nagarajan and Dr. G. Ramakrishnan
Contents
Foreword xxiii
Chapter 1 Basic concepts – units and standards 1
1.1 Introduction 1
1.2 Instrumentation 1
1.3 Measurement system 2
1.4 General concepts of measurement 2
1.4.1 Measurement methods 3
1.4.2 Generalised measurement system and its elements 5
1.4.3 Three stages of a generalized measurement system 7
1.4.4 Applications of measuring system instruments 8
1.5 Programmable logic controllers (PLC) 9
1.5.1 Four steps in the PLC operations 10
1.5.2 Programming language in PLC 11
1.6 Units and standards 13
Chapter 2 Instrumentation 15
2.1 Introduction 15
2.2 Instrumentation systems 15
2.3 Analogue instrumentation system 15
2.4 Digital instrumentation system 16
2.5 Transducers 18
2.6 Classification of Transducers 18
2.6.1 Basic requirements of a transducer 18
2.6.2 Selection of transducers 19
2.6.3 Potentiometers 19
2.6.4 Basic arrangement of a linear potentiometer 20
2.6.5 Displacement transducers 20
2.6.6 Linear variable differential transducer (LVDT) 21
2.7 Measurement of force and pressure 23
2.8 Measurement of temperature 24
2.9 Strain gauges 25
2.10 Terms and definitions used in instrumentation 26
Chapter 3 Measuring devices in textile mills 29
3.1 Introduction 29
3.2 Angular motion measurement in textile machines 29
3.2.1 Revolution counter and timer 30
3.2.2 Electrical type 30
3.3 Tachometers 32
3.3.1 Types of tachometers 33
3.3.2 Inductive tachometer (Non-contact type) 34
3.3.3 Photoelectric type tachometer (non-contact) 34
3.3.4 Contact type tachometer 35
3.4 Stroboscope 35
3.5 Flow measurement 37
3.5.1 Laser Doppler Anemometer 38
3.6 Torque measurement 40
3.6.1 Absorption dynamometers 40
3.6.2 Hydraulic dynamometer 41
3.7 Pressure measurement 42
3.7.1 Differential pressure 42
3.7.2 Piezometer 43
3.7.3 Manometers 44
3.7.4 Elastic transducers used for pressure measurement 45
3.8 Sound measurement 45
3.9 Measurement of vibration 48
3.9.1 Simple vibration instruments 48
3.10 Seismic instrument 49
3.11 Instrument transducers: principle and application in textile machines 51
3.11.1 Active instrument transducers 52
3.12 Passive instrument transducers 57
3.13 Humidity measurement 60
3.13.1 Sensors based on capacitive effect 61
3.13.2 Sensors based on resistive effect 62
3.13.3 Pros and cons of these two types of sensors 63
3.14 Measurement of air pressure inside the duct in spinning mills 64
3.14.1 Pressure measurement using Pilot tube 66
3.14.2 Measurement of dynamic pressure using Pilot tube 66
3.14.3 Measurement of static pressure 67
3.15 Measurement of viscosity of size paste in sizing machines 68
3.15.1 Viscometer 69
3.16 Stepper motors 69
3.16.1 Variable reluctance type stepper motors 71
Chapter 4 Instrumentation in textile testing equipments 75
4.1 Introduction 75
4.2 Digital fibrograph 75
4.3 High volume instruments (HVI) 76
4.4 AFIS (Advanced Fibre information System) 82
4.5 Vibroscope 84
4.6 Variable capacitance type 85
4.6.1 Capacitance method 86
4.6.2 Optical methods 87
4.7 Yarn hairiness 88
4.8 Determination of contaminants in the yarn 89
4.8.1 Practical importance of dust and trash particles 90
4.9 OM sensor 92
4.10 Universal tensile tester 93
4.11 Moisture measurement 94
4.12 Measurement of tension 94
Chapter 5 Control systems in ginning 97
5.1 Introduction 97
5.2 Ginning the seed cotton 97
5.2.1 Reasons for monitoring ginning process 98
5.2.2 Quality control in ginning process 99
5.3 Uster Intellegin – System features 99
5.4 Advantages of Uster Intellegin-M 102
5.4.1 Field trials with and without monitoring
system in ginning 102
5.5 Improvement in strength values of cotton fibres 103
5.6 Improvement in uniformity values 104
5.7 Improvement in fibre properties like neps, seed coat neps 104
5.8 Benefits for ginners 105
Chapter 6 Control systems in blow room line 107
6.1 Introduction 107
6.2 Material flow control 107
6.3 Optical monitoring system 110
6.4 Control systems in feeding unit in blow room line 112
6.5 Foreign matter removal in blow room line 113
6.6 Automatic heavy part separator by SEPAROMAT ASTA 114
6.7 Metal part extractors 116
6.8 Electronic metal extractors 117
6.9 Fire control systems for a modern spinning plant 118
6.10 ARGUS fire control system 119
Chapter 7 Foreign fibre detection in blow room 121
7.1 Introduction 121
7.2 Foreign material in the cotton 121
7.3 Effect of foreign fibre material in textile production chain 123
7.3.1 Degree of contamination in cotton bales 123
7.4 Size and appearance of foreign fibre matter in the textile supply chain 124
7.5 Appearance of foreign fibres in spinning mills 126
7.6 Frequency of foreign material and elimination methods 127
7.6.1 Effect of foreign fibre particles on the spinning process 127
7.7 Optimum strategies for foreign fibre detection and elimination 128
7.8 Cotton selection 130
7.9 Contamination removal systems in blow room line 130
7.10 Contamination detection and elimination systems 131
7.10.1 Arrangement of optical sensors 133
7.10.2 Positioning of Uster Opti Scan in the blow room line 133
7.10.3 Contamination removal system in Jossi vision shield 135
7.10.4 Positioning of contamination removal system
in blow room sequence 136
7.11 Elimination of foreign fibres of polypropylene type 137
7.11.1 Benefits of SECUROPOP-SP-FP 139
7.12 Securomat SCFO 139
Chapter 8 Monitoring system in carding machines 143
8.1 Introduction 143
8.2 Auto levellers in carding 143
8.3 Classification of auto levellers 143
8.4 Principle of short-term auto levelling 144
8.5 Auto levelling at the feed zone 145
8.6 Principle of medium-term auto levelling 146
8.7 Principle of long-term auto levelling 147
8.8 Measuring device in card 148
8.9 Measuring device at the delivery 149
8.10 Delivery speed monitoring 150
8.11 Cylinder speed monitoring 150
8.12 Flats monitoring 151
8.13 Doffer regulating system 152
8.14 Quality data on the carding machine 153
Chapter 9 Control system in draw frames 155
9.1 Introduction 155
9.2 Control system 155
9.3 Auto levellers 159
9.3.1 Concept of auto levelling 160
9.3.2 Classification of auto levelling 160
9.3.3 Levelling system in draw frame 165
9.4 Electronic data storage 166
9.5 LED display of levelling motion 167
9.6 Sensing mechanism 169
9.7 Auto levelling of RSB draw frames 171
9.8 Adaptation “C” 174
9.9 Assessment of auto levellers performance 175
9.10 Setting the auto leveller 179
9.11 Servo drive 179
9.12 Sliver test 180
9.13 Quick test on auto leveller 182
9.14 Economics of auto leveller 184
9.15 Online monitoring system at draw frames 184
9.16 Sliver watch 185
9.17 Thick places in sliver 185
9.18 Long-term analysis of thick places 186
9.19 Quality parameters checked by Uster sliver data 187
9.20 Integrated monitoring system 189
9.21 USTER sliver guard 190
Chapter 10 Monitoring in combers 193
10.1 Introduction 193
10.2 Function of UQM 193
10.3 Delivery speed measurement by proximity switch 194
10.4 Light barrier and light scanner 196
10.5 Light barrier for sliver congestion 196
10.6 Light barriers at the suction duct 197
10.7 Light scanner for monitoring the single lap 198
10.8 Light barriers for individual head monitoring 198
10.9 Table funnel monitor with one light barrier 200
10.10 Monitoring of thin places in the comber sliver 200
Chapter 11 Monitoring in speed frames 203
11.1 Introduction 203
11.2 Purpose of online monitoring 203
11.2.1 Online monitoring devices in speed frame 204
11.2.2 Photo sensor in the creel section 204
11.2.3 Photo sensor at the front roll delivery 204
11.3 Individual roving monitoring 205
11.4 Roving tension control 205
11.5 Roving stop motion 206
11.6 Pneumatic loading in the drafting system in speed frame 208
11.7 Quality monitoring in speed frames – significance 209
11.8 Quality monitoring in speed frames – present status 210
11.9 Premier Roving Eye 5000 – On line monitoring system 212
11.10 Quality assurance with Premier Roving Eye 5000 214
Chapter 12 Monitoring systems in ring frames 215
12.1 Introduction 215
12.2 Salient features of modern online instrument 215
12.3 Elements of ring data system 216
12.4 Functions of travelling sensor in ring data system 217
12.5 Central unit of the ring data system 219
12.6 Analysis of ring data reports 220
12.7 Stationary single spindle monitoring system 224
12.8 Sensors and proximity switches in ring spinning machines 225
12.9 Proximity switches for braking spindle drive motor 226
12.10 Proximity switches for drafting system motor speed 226
12.11 Proximity switch for spindle speed 227
12.12 Proximity switch for delivery drafting roller 228
12.13 Solenoid valves for supplying air pressure to the drafting system 228
Chapter 13 Online monitoring system in automatic cone winders 231
13.1 Introduction 231
13.2 Basic requirements of yarn clearing installations 231
13.3 Classifying systems 232
13.4 Setting of the clearing characteristics 233
13.5 Determination of optimum yarn clearing conditions 234
13.6 Auto coner informator 235
13.6.1 Advantages of online monitoring system 236
13.6.2 Setting of the yarn clearing installation 236
13.7 Classifications of yarn clearers 236
13.7.1 Capacitance type clearer 237
13.7.2 Photo electric clearer 237
13.7.3 Disturbing factors in both methods of measurement 238
13.8 Economical and technical problem on yarn clearing 240
13.9 Method of cutting the fault in the yarn clearer 241
13.10 Explanation of the data output of the classifying system 242
13.11 Classification matrix for foreign fibres 244
13.11.1 Fundamentals of foreign fibre detection 246
13.11.2 Measuring principle of yarn Master 900 247
13.11.3 Classification of foreign fibres in Loepfe Yarn Master 248
13.12 Scatter plot for foreign fibres 249
13.13 Sensors for monitoring all the bobbins in winding machines 250
13.14 Bench marking of Classimat classification 254
13.14.1 Advantages of yarn clearer installations in auto winders 254
13.14.2 Computer aided yarn clearing (CAY) 255
13.14.3 Online monitoring of the automatic cone winders 255
13.15 USTER CONE DATA production data information system 255
13.16 Knotters and Splicers in auto winders 257
13.17 Tensor constant density winding process by Savio 261
13.17.1 Semi-conductor device (TRIAC) 262
13.18 Wax disc sensors in winding 262
Chapter 14 Sensors in rotor spinning 263
14.1 Introduction 263
14.2 Sensors for monitoring the running yarn in rotor spinning 263
14.3 Auto-piecing process in rotor spinning 264
14.4 Online monitoring of yarn faults in rotor spinning machine 265
14.4.1 Measuring head 265
14.4.2 Evaluation unit 266
14.4.3 Virtual yarn clearing 267
14.4.4 Yarn fault classification 267
14.4.5 Setting of sensitivity levels 268
14.4.6 Translator 270
14.4.7 Setting values for short thick places N and S 271
14.4.8 Settings for long thick places (L) 272
14.5 CVm – UPG alarm 273
14.6 Mean value alarm 274
14.7 Display of yarn faults detected 274
14.8 Spectrogram analysis 275
14.8.1 Spectrogram 275
14.8.2 Spectrogram alarm 276
14.8.3 Attributes of Q – Pack in rotor spinning machine 277
14.8.4 Moiré channel (MO) 278
Chapter 15 Sensors and their application in spinning machines 279
15.1 Introduction 279
15.2 Electronic sensors 279
15.2.1 Classification of transducers 279
15.2.2 Selection of transducer 280
15.3 Sensors in carding 282
15.4 Sensors in draw frame 283
15.4.1 Sensors in combers 283
15.4.2 Sensors in speed frames 283
15.5 Sensors in ring frames 284
15.6 Sensors in auto winders 284
15.7 Sensors in textile machinery 285
15.7.1 Working principle 287
15.7.2 Photoelectric sensors 287
Chapter 16 Electronic controls in weaving preparatory and weaving machines 291
16.1 Introduction 291
16.2 Developments in sizing machine controls 292
16.2.1 Controls and instrumentation 292
16.2.2 Electronic control systems in sizing machines 294
16.3 Computer controls in weaving preparatory and weaving machines 295
16.3.1 Pre-wet sizing 297
16.3.2 Sectional warping machines 298
16.4 Denting 299
16.4.1 Semi-automatic reaching in machines 301
16.4.2 Automatic knotting or tying- in 301
16.4.3 Automatic tying machine 302
16.4.4 Stationary tying-in machine 302
16.5 Advantages of electronic and control systems in textile industry 304
16.5.1 Slim through light sensor (STS) 305
16.5.2 Electronic colour selector (ECS) 306
16.5.3 Pre-winder switch off (PSO) 307
16.5.4 Electronic yarn tension control 307
16.5.5 Automatic start-mark prevention (ASP) 308
16.6 Control system in warp let-off motion in looms 309
16.6.1 Electronic control system 310
16.7 Drive and control in modern weaving machines 312
16.8 Stäubli Jacquards 314
16.8.1 Basic construction features of Stäubli Jacquard 315
16.8.2 Low shed position 316
16.8.3 Quick link 317
16.9 Modern developments in weaving machinery 318
16.9.1 Developments in shuttleless machines 318
16.9.2 Developments in projectile machines 319
16.9.3 Developments in air-jet weaving 320
16.9.4 Modification in weft insertion system 320
16.9.5 Developments in rapier weaving 322
16.10 Premier loom eye and Uster loom data 324
16.10.1 Information from loom data 325
16.10.2 Advantages of the loom data 327
16.11 Online weft yarn tension monitor 328
16.11.1 Optical electronic weft feeler 329
16.12 Weaving of yarn-dyed figured cloth 330
16.13 Automatic fabric inspection 332
16.14 Applications of computers in the weaving mills 332
16.14.1 Manual monitoring 333
16.14.2 Monitoring of loom productivity 335
16.14.3 Computer application in spinning mills 335
16.15 Applications of microprocessors for measurement and control in weaving 336
16.15.1 Interconnecting system of multiplexer 337
Chapter 17 Advancements in on-line monitoring and control of parameters in knitting and sewing processes 339
17.1 Introduction 339
17.2 Knitting machines 339
17.3 CAD/CAM in knitting 342
17.4 Industrial sewing machines 346
17.5 Electronics in warp knitting 348
17.6 Electronic beam control let-off motion 350
17.7 Electronic weft insertion on weft insertion machines 351
Chapter 18 Online control in wet processing 353
18.1 Introduction 353
18.2 Wet processing 354
18.3 Developments in the new version online colour measuring spectrophotometer with new instrumental control 356
18.3.1 Multi variables in dyeing process and colour controllers 359
18.3.2 Colour definitions 360
18.3.3 Metamerism 361
18.3.4 Non-contact colour measurement 362
18.4 Computer colour matching system 362
18.4.1 Implementation of computerised colour matching 363
18.5 Computer colour control in batch dyeing operations 364
18.5.1 Structure of a dyeing process control system 366
18.6 Control system for the dye house 367
18.6.1 Individual control 369
18.6.2 DC control and monitoring 371
18.6.3 Dye house automation 372
18.7 Yarn package dyeing machines 373
18.7.1 Aero-flow piece dyeing machines 375
18.7.2 Fluid flow in the cylindrical and conical packages 376
18.8 Digital printing 377
18.8.1 Selection of right ink and fabric combination for digital printing 378
18.8.2 Digital textile printing process 378
18.8.3 Pre-treatment/coating 379
18.8.4 Benefits of digital textile printing 381
18.9 Textile finishing machinery 381
18.10 Computer integrated manufacturing in textile factories 382
18.10.1 CIM in spinning 385
18.10.2 CIM in weaving 385
18.11 CIM in dyeing 387
18.11.1 Yarn singeing 389
18.11.2 High efficiency singeing burners 390
18.11.3 Unsinged yarn lengths 391
18.11.4 Waxing during singeing 392
18.11.5 Dust control 393
Chapter 19 Pneumatic and hydraulic control valves 395
19.1 Introduction 395
19.2 Operating procedure of pneumatic valves 395
19.3 Solenoid operated valve 396
19.3.1 Pneumatic flapper valves 397
19.4 Types of compressors 398
19.4.1 Centrifugal compressor 398
19.4.2 Axial flow compressor 399
19.4.3 Diaphragm compressor 400
19.4.4 Multi stage compressor 401
19.4.5 Compressed air distribution in spinning mills 402
19.4.6 Compressor efficiency 404
19.4.7 Compressed air in textile industries 405
19.4.8 Applications of compressed air in textile industry 405
19.4.9 Principles of compressor operation 407
19.5 Hydraulic valves 409
19.5.1 Nozzle valve 412
19.6 Pressure switches 414
19.7 Automation in material handling 415
References 416
Index 419