International Journal of Engineering and Advanced Research Technology (IJEART) ISSN: 2454-9290, Volume-4, Issue-7, July 2018 Automatic textile sizing machine using PLC, VFD, HMI Praful Chudasama, Vardhil Shah, Parmar Yash, Tushar patel, Nevil solanki Tensile or breaking strength of cellulosic yarn is Abstract— The textile sizing machine is used for size of increased by sizing. polyester, viscous and cotton yarns. These are many factors Elasticity of the yarn is also increased. which effect the size of yarn like temperure, chemicals, speed of By adding size materials, yarn weight is increased. motor, bobbin winding tension and synchronization of motors. As we know as to control mention above factors we have to To increase the frictional resistance. develop a fully automatic systems for textile sizing machine. for Projected fibers are removed by this process. this purpose we are going to used PLC,HMI and VFD drives ,In To reduce electrostatic formation. our project first we should control optimum temperure with respect to speed to maintain set temperure of yarn, for III. PROPERTIES OF SIZING YARN controlling the speed of motor we will use VFD drives. For speed control of motor, synchronization of motor, set point of winding Generally size ingredients are used for warp yarn but tension and to control the pressure of size box we used VFD sometimes it applies on weft yarn. Anyhow, by applying size drives based motor system. We also provide auto cut-off of ingredients on the yarn, following properties are obtained. machine when bobbin is full of desired level of yarn using Properties of sized yarns are given below: proximity sensor. In our project we will develop automatic Higher elasticity textile sizing machine using PLC, HMI and VFD drives. Higher yarn strength Lower flexibility Index Terms— PLC, VFD, HMI, Textile sizing machine, Automation Lower extension or elongation Lower frictional resistance I. INTRODUCTION Increased smoothness Less weakness Textile sizing machine is basically used to do chemical Insensible to over drying coating on yarns. Sizing is the most important terms for weaving technology. After winding and warping, sizing of Less hairiness yarn is done during beam preparation. Sizing is done by So, size ingredients change the physical properties of applying various types of size materials on the yarn. During cellulosic fibers which is used for making a weavers beam. application of size materials steam is needed CHEMICAL PUMP TAKE UP MOTOR MIXING MOTOR . Fig-1 sizing machine OILER BLOWER MOTOR WINDER Sizing is a protective process. The process of applying a protective adhesive coating upon the yarns surface is called sizing. This is the most important operation to attain Fig-2 Electrical block diagram of the sizing machine maximum weaving efficiency especially for blended and filament yarns. Sizing is called the heart of weaving The Electrical block diagram of the sizing machine is mainly divided in to 5 zones. First zone consist the take up II. PURPOSE OF SIZING motor which is used to take number of yarns approx 10000 to 14000 from the creel. The second zone consist two number of Sizing is done during beam preparation for getting some motors. One is to used to run the chemical pump and another advantage of weaving. Sizing has lots of objects which are is mixing motor. Chemical pump is used to take the chemical given below: from downwards to upwards. The chemical which is used for To improve the weave ability of warp yarn by the coating is polyvinyl alcohol, modified starch. which has making it more resistance to action of weaving like property like glue. so we have to continuous mixed it for this absorption, friction, tension etc. task we require mixing motor. The third zone consist heating To maintaining good fabric quality by reducing process, for which have to run the blower for this we require hairiness, weakness and by increasing smoothness the blower motor. After the heating process the yarn becomes and absorbency of yarn. dry and brittle. so to avoid or to decrease the breaking of yarns 5 www.ijeart.com Automatic textile sizing machine using PLC, VFD, HMI we have to do fixed amount of oil coating on yarns, so the . To control desired level of temperature with respect next zone consist oiler motor. The last Zone consist winder to speed of machine motor which one is used to wound the sized yarns on the . To control the bobbin winding tension bobbin. Zone wise constant stretch control . Synchronization of motor for improving system IV. RELATION BETWEEN SPEED AND TEMPERATURE efficiency . Control the pressure of chemical size box machine . To develop auto cut off system when bobbin is full of desired level VI. PLC Fig-3 PLC block diagram What Is PLC?(Programmable Logic Controller) The main problem in the sizing machine is that the temperature of combustion chamber will not maintain A PLC is an industrial control system that constant, due to this the quality of the yarn will very according continuously monitors the state of input devices and to the variation in the temperature makes decisions based upon a program to control the To overcome this we used controlling panel which contain state of output devices. mainly three drives to control take up motor, oiler motor, winder motor. PT100 which is RTD used to measure the Types of PLC. instantaneous temperature of combustion chamber. we also Compact - i/p & o/p both are on one device include the PLC & HMI which both are interconnected for Modular - i/p & o/p both are on different device bilateral communication. PLC received the electrical output Hybrid - combination of compact and modulator of controller which gives the instantaneous value of temperature of combustion chamber. PLC detect the error Limitation of PLC between the actual temperature and the reference temperature. There is to much work required in connecting wires This error signal it gives to the winder drive. According to the There is difficulty with changes or replacement error winder drive very the speed of the winder motor. All When a problem occur hold up time is indefinite, three VFD are interconnected so take up and oiler drive also usually long very the speed according to the variation in the speed of VII. VFD winder drive. A Variable Frequency Drive (VFD) is a type of AC HMI used to display the what is actual temperature of the motor controller that drives an electric motor by combustion chamber and we can also very the reference varying the frequency and voltage supplied ratio to temperature. the electric motor. Other names for a VFD are Due to variation in the temperature the parameter which are variable speed drive, adjustable speed drive, changed by VFD is given below. adjustable frequency drive, AC drive, and inverter. Frequency is directly related to the motor’s speed Table -1: VFD PARAMETER (RPMs). In other words, the more the frequency, the faster the RPMs go. If an application does not require TEMPERATURE FREQUENCY VOLTAGE SPEED an electric motor to run at full speed, the VFD can be 110/220 50 440 1375-1500 used to change the frequency and voltage ratio to 90/110 39.5 343.2 1186-1375 meet the requirements of the electric motor’s load. As 70/90 29 259.6 886-1186 the application’s motor speed requirements change, 50/70 20 183.04 625-886 the VFD can simply turn up or down the motor speed to meet the speed requirement. V. OBJECTIVE 1. Modes of VFD drives [A] Open Loop Vector 1. We will control following parameter using PLC and It changes the frequency with respect to feedback of running VFD drives speed 6 www.ijeart.com International Journal of Engineering and Advanced Research Technology (IJEART) ISSN: 2454-9290, Volume-4, Issue-7, July 2018 To change the frequency it consider mainly three parameters Drives rating (A) No load speed (B) measured speed (C) torque characteristic [1] Take up drive 09 Amp YASKAWA V1000, Choke 5 Hp, MCB 16 A [B] V/F Ratio Constant [2] Oiler drive 04 Amp YASKAWA J1000, Choke 1 Hp, It change the ratio of V/F to keep the torque constant MCB 6 A [3] Winder drive 11 Amp YASKAWA A1000, Choke 5 Hp, MCB 16 A VIII. HMI contactor and OLR rating Human machine interface (HMI) – also known as User [1] Blower 16 A 3 phase, OLR 4 to 7 Amp Interface (UI), or Man Machine Interface (MMI) – consists [2] Size pump 6 A 3 phase, OLR 2.5 to 4 Amp hardware and software solutions for information exchange [3] winder cooling fan 6 A 3 phase, OLR 0.7 to 1 Amp and communication between machines and a human operator. Main MCB 63 Amp, DBR 100 E/ 1000W HMIs enable control, management and/or visualization of device processes and can range from simple inputs on a touch X. DESCRIPTION OF FLOWCHART display to control panels for highly complex industrial we used controlling panel which contain mainly three drives automation systems. HMIs can be found in multiple locations to control take up motor, oiler motor, winder motor. PT100 such as portable handheld devices, on machines, centralized which is RTD used to measure the instantaneous temperature control rooms, as well as factory floor machine and process of combustion chamber. we also include the PLC & HMI control. Applications include industrial and building which both are interconnected for bilateral communication. automation, digital signage, vending machine, medical, PLC received the electrical output of controller which gives automotive, and appliances. the instantaneous value of temperature of combustion chamber. PLC detect the error between the actual temperature and the reference temperature. This error signal it gives to the IX.