Professional Documents
Culture Documents
Hamdard University
BY
Project Advisor
Engr. Mehr-un-Nisa
(Usman Institute of Technology)
The designers urge to design cheap, reliable and less time consuming
prototypes before finalizing any product so that they can evaluate the design by
finding its flaws and to overcome it before going to make product immense.
PLC controller. The basic theme or idea of this product is to promote Pakistani
cultural style of dressing. Research work and report of this product contains the
designs before taking it to large scale so that any flaw or error could be rectified.
The machine will be given the specific embroidery design through Human
Machine Interface (HMI) software as an input and process it in a linear PLC and it
will embroider the design on the attached cloth as an output which can be treated as
Variety of shapes can be designed on the HMI software that will contain the
same hardware which will be used in our project or a different choice of a controller
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DEDICATION
helped us in achieving our goal and at last but not the least our “Friends” who
“That man can have nothing but what he strives for; that (the fruit of) his
striving will soon come in sight: Then will he be rewarded with a reward
complete.”
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ACKNOWLEDGEMENT
First of all we would like to thank The Almighty ALLAH, Who gave us the
successfully.
Secondly, we are very much thankful to our Internal Engr. Mehr-un-Nisa who
helped us in our project, fixed the problems we faced while making our project
We would also like to thank our Project coordinator Engr. Atif Fareed for his
kind and consecutive support. Besides we also want to thank, Engr. Ahsan Ahmed
Farooqui, Engr. Sameer Ahmed, Engr. Hammad Munami, and Engr. Asif
We would also like to thank our families who strengthened their undying support
towards us, during the course of this report and managed during our absences.
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PREFACE
Automated Embroidery Machine is a time saving project and also very helpful to
Our project is very effective in industry as in industries need this kind of automated
machines that are less time consuming and more product generating.
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TABLE OF CONTENTS
Title Page #
1.1 Introduction 09
1.2 Objective 10
1.3 Features 11
1.4 Aim 11
1.5 Motivation 11
2.1.6 Potentiometer 21
2.1.8 Transformer 23
2.1.9 Relay 24
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2.1.10 U-Sensor 25
2.1.11 AC Motor 26
3.1 Working 32
3.2 Programming 33
3.2.4 U-Sensor 34
4.2 Sensor 37
4.3 Stitching 37
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Chapter # 06—Future Recommendations ……... 40
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CHAPTER # 01
PROJECT INTRODUCTION
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CHAPTER # 01
PROJECT INTRODUCTION
1.1 INTRODUCTION
Every culture has its own traditional dressing and fashionable clothing
designs. Manufacturers bring new trends and styles to make these dressings
the people of various regions but one thing is common in dressings of these
regions and that is embroidery and mirror work. Most of the embroidery
work is done manually by women folk and men. When this embroidery work
goes outside the Pakistan, it also becomes a reason of attention for people
PLC to reduce human labour. This project is also able to do as much work as
hundreds of men do manually, less time consuming and can embroider the
factories also prefer automation. Automation can reduce the human effort
and can consume lesser time in performing the same task which is done
manually.
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Here we also prefer automation of embroidery that can help us to reduce
Our aim was to create an automated project that will consume lesser time,
cost and labour. And also try to make it as smaller in size as we can because
1.2 OBJECTIVE
Use PLC that can work accurately with stepper motors and can
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1.3 FEATURES
human labour.
1.4 AIM
human effort, labour cost and consume lesser time in an effective and
1.5 MOTIVATION
We have chosen this project because of its unique working and to promote
have a lot of things and components in this project to learn about and that
We have learned working and using of many components which are used in
this project as well as which are not used in this project because we had to
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compare between motors and sensors to select the suitable one for our
project.
PLC programming.
Using U-sensor.
Controlling AC motor.
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1.7 BLOCK DIAGRAM
Components Cost
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1.9 TIME FRAME
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CHAPTER # 02
PROJECT DESGIN
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CHAPTER # 02
PROJECT DESIGN
FBs-
Specification FBs-20MAR
20MAT/J
High speed (100KHZ) 2 points
Medium speed
4 points
Digital Input 24VDC (20KHZ)
Medium speed
6 points
(Total 5KHZ)
Relay 8 points ─
High speed (100KHZ) ─ 2 points
Digital
Medium speed
output Transistor ─ 6 points
(20KHZ)
Low speed ─ ─
1 port (Port0, USB or
Built-in
RS232)
Communication Port
2 ports (Port1~2, RS485 or
Expandable
RS232 or Ethernet)
Calendar optional
Built-in power supply SPW24-AC/D12/D24
Dimension 7.62mm fixed terminal block
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2.1.2 5 – Phase Stepper Motors:
We are using two 5-phase stepper motors to move the ball screws in
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5 Phase Stepper Motor vs 2 Phase Stepper Motor:
There are two key differences between 2-phase and 5-phase motors. The first
rotor. The rotor in turn is made up of three components; rotor cup 1, rotor
magnetic poles with small teeth, while the 5-phase motor stator is made up of
10 magnetic poles. The poles in the stator are each provided a winding.
The second difference between 2-phase and 5-phase is the number of phases.
A 2-phase motor has two phases, an "A" phase and a "B" phase, while a 5-
phase motor has five phases. Essentially, the number of phases refers to the
rotor.
Structurally, the 5-phase motor is not that different from the 2-phase motor.
The rotor in both motors has 50 teeth. The difference is that because the 5-
phase motor has 10 poles, 2 per phase, the rotor only has to move 1/10 of a
tooth pitch to line up with the next phase. In the 2-phase motor, the rotor has
to move 1/4 of a tooth pitch to line up with the next phase (8 poles, 4 per
phase).
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This results in the 2-phase having 200 steps per rotation, 1.8° per step, while
the 5-phase has 500 steps per rotation, 0.72° per step. The increased
micro stepping driver, the 5-phase motor can make steps as small as
0.00288°, however, position accuracy and repeatability are still subject to the
2 Phase Motor
5 Phase Motor
make step size more précised and motors can run more smoothly.
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2.1.4 Sewing Machine:
Precision ball screws have a number of bearing balls that transfer the load
The thread form in which the bearing balls ride is an ogival shape formed
from two arcs of the same radius with offset centers. This form is also
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We have used two ball screws in our project. Both are attached to the
stepper motors respectively. One stepper motor rotates the ball screw for x
2.1.6 Potentiometer:
A potentiometer,
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The measuring instrument called a potentiometer is essentially a
name.
load.
sewing machine.
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Third for y direction
We have used to limit the iron frame into 5 inches. So that it cannot
2.1.8 Transformer:
Step down
transformers are
designed to
reduce electrical
voltage. Their
primary voltage is
down" the voltage applied to it. For instance, a step down transformer
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Step down transformers are made from two or more coils of insulated
one coil
(frequently called
the primary or
input) it
magnetizes the
induces a voltage
(frequently called
the secondary or
transformation.
motors that we are using work at 110 volts. The transformer converts
2.1.9 Relay:
electric current that can turn on or off a much larger electric current.
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Electrical Relays however, are
“Contactors”.
2.1.10 U-sensor:
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2.1.11 AC Motor:
(AC). The AC
motor
commonly
consists of
two basic
parts, an
outside
stationary
stator having
coils supplied
with
alternating
current to
produce a
DC or AC electrical windings.
We have used AC motor with sewing machine, that helps to run the
sewing machine with PLC signal as well as it can vary the speed of
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Specification:
1. 100 W (Watt)
2. 220 V (Voltage)
3. 50 Hz (Frequency)
4. 0.5 A (Current)
5. 6000 RPM
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2.2 MECHANICAL DESGIN
assembled in a manner that they are moving the needle and thread
heads.
So at first we had decided to move the needle but it was very hard for
attached so the needle will run continuously while the frame will be
Designing a frame was easy for us but taking it to reality is also bit
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We have positioned this frame because of several important points:
very large.
Frame can move and rotate very smoothly as per the pattern.
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2.2.2 Machine Stand:
So, we tried to assemble all the components of our project over one
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CHAPTER # 03
IMPLEMENTATION
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CHAPTER # 03
IMPLEMENTATION
3.1 WORKING
connected with two stepper motors and in the other hand the stepper motors
are connected with two ball screws and both are connected to the iron
frame. One of the ball screws helps iron frame to move in x dimension and
the other helps to move in y dimension. Stepper motors have their drives;
the purpose of drives is to make micro step of the motors for more précised
and accurate stepping. There are limit switches attached to limit the
movements of the frame. We have used one step down transformer for
U-sensor is used for sensing the thread. If the thread breaks then it will
generate a signal to PLC and the stepper motors will stop immediately.
Embroidery designs are given by HMI and then the PLC processes it and
gives signal to stepper motors. The motors’ shaft moves the ball screws
according to the given embroidery pattern and then the iron frame that s
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attached to ball screws moves as well. AC motor starts working as it receives
a signal and then the sewing starts. Stitching will continue until it will
completely embroider the design or if the frame exceeds the limit or if the
thread breaks and u-sensor will give signal to PLC then the stitching will
3.2 PROGRAMMING
softwares.
in ladder logic.
programming of HMI.
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3.2.3 Limit Switches:
We have used four limit switches for the dimensions; x axis, -x axis,
exceed the limit of 5 inches as it will move out of the reach of needle
that is stitching.
PLC so that if any of the limit switches turns high, it will give signal
3.2.4 U-Sensor:
We have used U-sensor for thread, if the thread breaks the LED
signal to the PLC and PLC will turn off the motors due to an
error occurred.
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CHAPTER # 04
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CHAPTER # 04
problems, we
have faced
mechanical
structure of
our project
look like. We
have thought
at first to move the needle of the sewing machine through automated process
then realized that it was too hard to do with precision. Then we have decided
to attach stepper motors on the iron frame so we can move the iron frame
We have attached this iron frame with ball screws and on the other hand of
ball screws the stepper motors are attached and when the motor runs, it
Ball screws helped us to move the frame smoothly in x and y dimensions, the
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Finally, we have overcome this issue of mechanical structure and designed
it a physical look.
4.2 SENSOR
market and found it less expensive than thread sensors and also less
complicated to set up. We have used this sensor for thread, incase if the
thread breaks during the process so it will give signal to PLC and the
4.3 STITCHING
We have faced the last problem in stitching the cloth, as the stepper motors
have different speed and the needle moves at different speed. Then we have
to the sewing machine and hence, we were able to control the speed and
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CHAPTER # 05
TEST ANALYSIS
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CHAPTER # 05
TEST ANALYSIS
We have tested RPM of both the stepper motors and observed that their
Once we have done all the testing, we have assembled our machine
completely and at the end tested its final working. Our machine performed
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CHAPTER # 06
FUTURE RECOMMENDATIONS
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CHAPTER # 06
FUTURE RECOMMENDATIONS
We can also use motion cards for complex embroidery designs that can help
motors to rotate the plate in manner that can create circular patterns.
We have used only one thread head while in the future it can have several
thread heads for different colours of thread that can make embroidery more
attractive.
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CHAPTER # 07
FINAL OUTPUT
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CHAPTER # 07
FINAL OUTPUT
We are thankful to Allah for getting the desired output successfully. We have
successfully completed our project covering all its pre planned points and
designed mechanism.
The speed of stepper motors is successfully controlled and the motors have
been synchronized.
The HMI software is used to give the pre assigned embroidery designs.
Throughout the project we have learned about many things, technical as well as
ethical. Some of them are controlling and synchronizing motors, our confidence
have been developed by tackling the problems that we have faced in making of
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CHAPTER # 08
CONCLUSION
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CHAPTER # 08
CONCLUSION
approach provides a stable platform for industrial automation and by the help of
Human Machine Interface software it becomes easy for any individual to understand
and perform the task without difficulty. We are able to control and make the project
completely automated.
With all hard work and consistency we have completed the project Al hamdolillah
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CHAPTER # 09
REFRENCES
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CHAPTER # 09
REFRENCES
http://www3.panasonic.biz/ac/ae/fasys/sensor/micro/pm-53/
http://www.fatek.com/en/prod.php?act=view&no=3
http://www.orientalmotor.com/technology/articles/2phase-v-5phase.html
https://www.autonics.com/products/products_detail.php?catecode=03/02/01&db
_uid=121
https://en.wikipedia.org/wiki/Potentiometer
http://www.thomsonlinear.com/website/com/eng/products/ball_screws_and_lead
_screws/ball_screws.php
http://www.nookindustries.com/Product/ProductLine/Ball-Screw-Products
http://www.hiwin.com/ballscrews.html
https://en.wikipedia.org/wiki/Transformer
http://www.explainthatstuff.com/howrelayswork.html
http://www.electronics-tutorials.ws/io/io_5.html
http://ab.rockwellautomation.com/Sensors-Switches/Limit-Switches
https://en.wikipedia.org/wiki/Limit_switch
https://en.wikipedia.org/wiki/AC_motor
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