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INTERNATIONAL JOURNAL OF SCIENTIFIC & TECHNOLOGY RESEARCH VOLUME 8, ISSUE 10, OCTOBER 2019 ISSN 2277-8616 PIC Based Power Loom Automation Using IOT

P.Balasubramani, R.Krishnaveni

Abstract: In this paper, a novel method to automate shuttled power looms is proposed. Power loom is a mechanized loom, mainly meant for the purpose of weaving in textile industries. It considerably reduces human labor and wastage. Hence it helps to ensure high quality cloth production, monitoring and measurement. It provides automatic warp and weft error detection and automatic weft replenishment. This module uses PIC16F877A to provide the necessary automation of the shuttled power looms, with immediate termination of its motor operation in case of any weft or warp errors. Also the amount of woven cloth is ultimately displayed in LCD.

Keywords: weft, warp, single and double pick, PIC16F877A Proximity sensor, Control switches, Phototransistor, error detection and indication, production monitoring. ————————————————————

I. INTRODUCTION II. EXISTING SYSTEM Power loom is a mechanized loom used for weaving yarns in The existing system for the automation of the power looms, textile industry. It uses a drive shaft for power and became a was established many years ago. This system, though, it has key development in industrialization of textile industry during many advantages, it suffers from serious drawbacks also. In early industrial revolution. Invented by Edmund Cartwright in this, IC 555 timer is used to control the entire automation of Great Britain, in 1784, power looms made the process of such a huge mechanized looms. In this system, IC 555 timer weaving and creating textiles much quicker than with the provides the necessary automation. The warp and weft errors hand driven looms. This made the power loom to become one are detected and multiplexed to a signal generator, whose of the defining machines in the industrial revolution. This tool output is given to the timer IC. Since IC 555 has only a single was further refined after 47 years by Ken worthy and input, multiplexing multiple inputs become a tedious job. Also Bullough, a design which was partially automatic. In 1895, this system has a status indicating unit, comprising of three many looms driven by electric engine were invented and in LEDs (green, red, and yellow). The block diagram of existing the beginning of 1930s, each individual machine was driven model is given in figure.1. The weft error detection is made by an electric motor. There are two types of power looms: possible by using an electro-magnetic setup. This mechanism shuttle and shuttleless power looms. In this paper, automation fails to stop the loom immediately since it takes a few of shuttled power loom is proposed. The terms warp and weft durations for the coil to become an electro-magnet and so the are two key terms used in the process of weaving. In literal shuttle takes a certain number of picks, even if the weft yarn sense, they are the technical terms for the two types of thread is broken. As a result, damaged fabric gets woven. In this used to weave a cloth. The warp is the tightly stretched system, MOC7811 is used. It is a position Encoder sensor, lengthwise core of fabric, while the weft is woven between the which is used to find position of the wheel. It consists of IR warp threads to create various patterns. Sometimes weft is LED and photodiode mounted facing each other enclosed in also called as the „filler‟ thread, since it fills in the desired plastic body. When light emitted by the IR LED is blocked design and also as „woof‟in some regions. The huge because of alternating slots of the encoder disc logic level of components of the loom are the warp beam, heddles, the photo diode changes. This change in the logic level can harnesses, shuttle, reed and take-up roll. In the loom, yarn be sensed by the microcontroller and give as the output to processing includes shedding, picking, battening and taking- controller. This sensor is used to give position feedback of the up operations. Shedding is the process of raising the warp loom. This model suffers from serious disadvantages. Weft yarns to form a loop, through the weft yarns. In modern yarn replenishment is absent. This system detects weft errors. looms, shedding process is carried out by heddle frame. In But it does not have accurate and precise control of weft picking, the filling yarn is inserted through the shed by a yarns. It also fails to facilitate production monitoring, shuttle (a yarn carrying device). A single crossing of the measuring and displaying the quantity of woven fabric in any shuttle from one side of the loom to the other is called as display devices. single pick and the second crossing to is original position I s called as double pick. In the process of battening, shuttle also moves through a frame called reed as it moves across the S I loom lying down the fill yarn. Conventional shuttle looms can G operate at a speed of about 150 to 160 picks per minute. The WARP N newly woven textile is rolled up on a beam. This process is STOP A called as taking up. To become fully automatic, loom requires L immediate stop motion if any warp or weft yarns break. G E IC 555 R WEFT N E M STOP E L ______R A Y A  P.Balasubramani, R.Krishnaveni T  [email protected] and [email protected] O  Assistant Professor R  Department of Electronics and Communication Engineering  KIT-Kalaignarkarunanidhi Institute of Technology Coimbatore-641 402 Fig.1. Block diagram of existing system

Since timer IC has only a single input, multiplexing multiple PIN diagram of PIC16F877A is given in fig.2.b. inputs using proper selection controls increases system complexity. Hence, hardware implementation is very complex WARP PRODUCTION DISPLAY and time consuming. Above all, this system is less reliable ERROR and accurate, as immediate seizing of loom operation is not possible. WEFT ERROR III. PROPOSED MODEL

In this paper, a PIC based automation circuit for shuttle WEFT STATUS looms, that facilitates automatic weft and warp stop motion is REPLENISH INDICA proposed. Also it provides automatic weft replenishment and TION has a warning system. It is a cost efficient and an intelligent PRODUCTION MCU UNIT system for automating the shuttle looms. This has MONITORING tremendously decreased the required man power and also ensures high quality woven fabric. The hardware consists S mainly of 6 units: Microcontroller unit, Input unit (Warp error START W R E M control, Weft error control, Weft replenishment, Production I T L monitoring, Control switches) and Output unit (Relay and STOP A C motor unit, Production display, status indication (LED and H Y Buzzer). The block diagram of the proposed model is given in PICK E fig.2.a. All the above units interact with each other to provide S necessary automation of shuttled power looms, which includes automatic error detection and weft yarn Fig. 2.a. Block diagram of proposed system replenishment.

A. Power supply unit For the functioning of any components, a power supply is the most basic requirement. In this module, 5V power supply is used.

B. Microcontroller unit (PIC 16F877A) Peripheral Interface Controller or Programmable Interrupt Controller a family of modified Harvard architecture microcontrollers made by Microchip Technology. It is a 40 pin IC and has an inbuilt 10 bit, 8 channel analog to digital converter. It exhibits high performance RISC CPU, only with 35 instructions. 3 All single cycle instructions except for branches, which are two cycles. It has an operating speed of: DC-20 MHz clock input and DC-200 nanoseconds instruction cycle. It has a FLASH program memory of 8K x 14 words, up to 368 x 8 bytes of Data Memory (RAM) and up to 256 x 8 bytes of EEPROM Data Memory. It has many other Fig.2.b. PIN diagram of PIC16F877a advantages like self-reprogrammable under software control, In-Circuit Serial Programming™ (ICSP™) via two pins, single- C. Warp error control unit supply 5V, in-Circuit Serial Programming, programmable code The major function of warp error control unit is to stop the protection and power saving sleep mode. loom when any of the warp thread breaks. This module consists of a long metal rod and numerous v shaped needles. Basically 4000 warp yarns are wounded over the roller beam. Each thread is provided with a metal needle just above them. The metal rod is placed beneath the group of warp yarns. The metal rod is separated into two by an insulator, one part is given a positive charge and other as negative. If any of the thread breaks during the process of weaving, the metal needle, placed just above the yarn falls over the rod, thus completing the electrical circuit. This error is constantly monitored and sensed. This type of error is called warp error and if such an error is sensed, the operation of loom is seized immediately. Ii is illustrated in fig.2.c.

ADC OF PIC IR LED – PHOTO TRANSISTOR

Fig 2.d Weft replenishment

F. Production monitoring and display unit Fig 2.c Warp error control In any commercial industries, the quality and quantity of finished products are very important, especially in textile D. Weft error control unit industries. The primary aim of any commercial textile industry The weft error control unit is used to stop the loom when weft is to produce maximum amount of undamaged fabric. But yarn breaks. This module makes use of inductive proximity manual measurement of the fabric woven by each power sensor. An inductive proximity sensor is a type of non-contact loom, is tedious. This module, proposed here, provides electronic proximity sensor that is used to detect the position constant measurement of woven cloth and the same is of metal objects. The sensing range of an inductive switch is displayed in a liquid crystal display. This module makes use dependent on the type of metal being detected. Ferrous of inductive proximity sensor for measuring the woven fabric metals, such as iron and steel, allow for a longer sensing and the resulting value is displayed in the LCD. The proximity range, while nonferrous metals, such as aluminum and sensor, as it is capable of detecting metals, is placed in copper, can reduce the sensing range by up to 60 percent. In contact with the warp roller beam. During the process of conventional looms, a shuttle weighing around a half a weaving, the roller moves here and forth. This number of kilogram is inserted through the warp shed to facilitate moves made by the roller, in turn gives the quantity of woven weaving. This shuttle carries the weft yarns. The weft thread fabric. In order to sense the number of movements made by is provided with a metal rod like structure. Each time a weft the roller beam, an inductive proximity sensor is used. This thread makes a single pick, it uplifts this rod and makes number is then converted into the quantity of woven fabric alternate sensor contacts. If the weft thread breaks or cut, and ultimately displayed in the LCD. then sensor output is continuous 1s, which in turn indicates that the loom has to be stopped immediately. G. Control switches and status indication unit A switch is an electrical component that can break an E. Weft replenishment unit electrical circuit, interrupting the current or diverting it from Weft yarn is bundled in a shuttle, which is approximately half one conductor to another. There are three push buttons used a kilogram heavy. During each single pick, the weft yarn in this system. They are Start, Stop and Pick. Start button is weaves in between the warp yarns in order to make the used to start the operation of the loom, i.e. to start the motor woven cloth. Unlike warp threads which are kept under high initially. As the name indicates the stop button is used to seize tension on the loom, the weft is not kept under the same the running of the motor, i.e. to terminate the operation of the amount of tension and therefore does not have to be loom. The pick button plays an important role in weaving. If constructed out of as strong of a yarn as the warp threads. only a small portion of the fabric has to be weaved with a This module uses a combination of IR LED and photo different color, say borders of sarees and dhotis, the pick transistor. An IR led is placed above the weft shuttle and button can be used. This button operates the loom for a phototransistor below it. Initially when the shuttle is fully discrete amount of time and stop the loom by itself. Status bundled with the weft threads, no light falls on the photo indication unit comprises of LEDs and a buzzer, which are transistor. As the yarn goes on decreasing, the intensity of used to indicate the working status of loom. When the Start light falling on phototransistor goes on increasing. When the button is pressed, the motor starts running, which is indicated weft yarn is completely used up, the intensity of light falling on by the glowing of Green LED. When the motor is stopped the phototransistor is maximum. The motor is stopped at the either by the Stop button or due to any weft or warp error, the nearest maximum intensity, i.e. before the yarn gets Red colored LED starts glowing and an alarm sound is given completely used up. This module is interfaced to the ADC by the buzzer. The Yellow colored LED gets lighted up during channel of the microcontroller in fig.2.d the picking process, i.e. when the motor is going to seize its operation.

H. Relay and Motor Unit Relay and motor unit is responsible for the smooth working of power loom machines. Rather they are solely responsible for

3145 IJSTR©2019 www.ijstr.org INTERNATIONAL JOURNAL OF SCIENTIFIC & TECHNOLOGY RESEARCH VOLUME 8, ISSUE 10, OCTOBER 2019 ISSN 2277-8616 the operation of power looms. In real time applications, 1 HP Figure 3 shows the defect in the weft thread. In the simulation 3 phase motors with 1440 and 960 RPM are used. Here in the defect is shown such that when weft thread is cut, the this prototype module, 12V relay and 12V DC gear motor are LCD shows the status as weft detected and machine stop. used. The circuit diagram of the model is described in the fig.3. IV CONCLUSION AND FUTURE WORK LCD1 LM016L In this paper, we proposed a method for automatic warp and

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U1 functions automatically with the help of IoT. In future, manual 13 33 D0 OSC1/CLKIN RB0/INT 14 34 D1 OSC2/CLKOUT RB1 35 D2 RB2 assistance in beam replacement and warp breaks can be RA02 36 D3 RA0/AN0 RB3/PGM RA13 37 D4 X1 RA1/AN1 RB4 RA24 38 D5 RA2/AN2/VREF-/CVREF RB5 RA35 39 D6 automated and multi looms can be controlled by use of RA3/AN3/VREF+ RB6/PGC 6 40 D7 WARP RA4/T0CKI/C1OUT RB7/PGD RA0 7 CRYSTAL RA5/AN4/SS/C2OUT 15 RC0 V12 RC0/T1OSO/T1CKI Solitary controller. RS 8 16 RC1 WEFT RE0/AN5/RD RC1/T1OSI/CCP2 RA1 RW 9 17 RC2 RE1/AN6/WR RC2/CCP1 EN 10 18 C2 C1 RE2/AN7/CS RC3/SCK/SCL 23 PROX 1 1nF 1nF RC4/SDI/SDA RA2 1 24 RED MCLR/Vpp/THV RC5/SDO 25 YELLOW RC6/TX/CK RL1 26 GREEN PROX 2 RC7/RX/DT D1 12V RA3 References DIODE 19 R1 RD0/PSP0 20 R2 RD1/PSP1 21 RD2/PSP2 [1] Alexandru A.M., De MauroA., Fiasché M., Sisca 22 RD3/PSP3 Q1 27 R1 RD4/PSP4 BC547 28 RD5/PSP5 F.G.,Taisch M.,Fasanotti L., Grasseni P., A smart 29 RD6/PSP6 30 RD7/PSP7 START PIC16F877A web-based maintenance system for a smart

RC0 st D2(K) manufacturing environment, IEEE 1 International STOP BUZ1 Forum on Research and Technologies for Society RC1

RL2 BUZZER D2 12V and Industry Leveraging a better tomorrow (2015), PICK DIODE

RC2 579-584. Q2 R2 BC547 [2] J.Freudenberger, M. Bossert, V. V. Zyablov S. Shavgulidze“Woven codes with outer warp: variations design and distance properties”, IEEE Journal on Selected Areas in Communications, 2001. Fig 3. Circuit diagram of PIC based automation of shuttled [3] Ren C. Luo, Jyh Hwa Tzou and Yi Cheng Chang power looms Intelligent Automation Laboratory Department of Electrical Engineering, National Chung Cheng The same is simulated using MPLAB IDE. MPLAB IDE University 160 Shang-Shing, Ming-Hsiung, Chia-Yi, supports multiple debugging tools in a single development Taiwan 621, R.O. “The Integration of 3D Digitizing paradigm, from the cost effective simulators, through low cost and LCD Panel Display Based Rapid Prototyping in-circuit debuggers, to full-featured emulators. This System for Manufacturing Automation” 2000. eliminates the learning curve when upgrading to tools with [4] M.W.Burton, J. S. Culver, “A Mechatronic approach increasing flexibility and power. The MPLAB IDE allows to: to the design of a flexible carpet loom”, IEE  Edit your source files (either assembly or C) Colloquium on Configurable servo Control Systems,  One touch assembles (or compile) and download to Volume 64, Issue 4, 2015. PIC micro emulator. [5] Jingfeng Shao, Zhanyi Zhao, Liping Yang, Peng  Easy debugging SongRemote Monitoring and Control System Oriented to the Textile Enterprise, IEEE Second International Symposium on Knowledge Acquisition and Modeling (2009). [6] Kim S., Lee J.S., Development of a versatile Controller System for textile machinery, Fibers and Polymers 12(4) (2011). [7] Li R., Liu C., Luo F., A design for automotive CAN bus monitoring system, Vehicle Power and Propulsion Conference (2008), 1-5. [8] Gurusamy Pandian P.G., Sarvanasankar S., Ramasamy S.N., Prevention of Fire Hazards and Control in South Indian Power Loom Industries using SHAPA Sensors, International Research Journal of Engineering and Technology 02(08) (2015). [9] Prasanna Kumar E., Karuppusamy P., Santhosh Kumar D., Sowndharsekar C., Venugopal S., Intelligent monitoring system for production management in powerloom, IJAREEIE 6(3) (2017). [10] Shao J.F., Qin L.S., Design of loom monitoring and management system based on C/S model, Journal of Fig 4.simulation output Textile Research 7 (2006). International Journal of Pure and Applied Mathematics Special Issue 946