Implementation of direct warping machine for experimental use

3.0 INTRODUCTION

Direct warping machine is available in Denim, woven dyeing, Terry towel and Hometex fabric
manufacturing industries. Also available in textile college and university as experimental
purpose. Because of warping is the preparatory part of the Denim, woven dyeing, Terry towel
and Hometex fabric manufacturing industries. And it is remarkable that usually warping
machines are imported for industrial purpose. Some warping machines are imported for
experimental purpose but these are also costly and big in size. For that reason, I have attempted
to do something regarding Implementation of Low-Cost Direct Warping Machine for
Experimental Use. It is possible to implement Low-Cost Direct Warping Machine in our
country without import from foreign. This is not extra ordinary work. But it will introduce the
students with a Practical experiments in University Level and also will make encourage and
courageous them to work industrial Automation System. In my project work I have developed an
electrical control system using microcontroller, PLC and HMI.

3.1 CONTROL FLOW CHART OF THE PROJECT

HMI

Yarn Break sensor/Stop motion

Emergency Stop

PLC

Encoder
Yarn length measure

Speed SensorDC motor Speed controller Relay Relay

DC motor for Beam drive

DC motor for Beam ChuckDC motor for Beam Lift

3.2 Explanation of control flow chart

  Desired length, beam lifting and beam chucking instruction set on HMI.
 Then the desired instruction takes PLC from HMI and makes decision according to
program.
 After beam lifting, beam chucking system will hold the beam then beam start to rotate.
 Speeds and Lengths will feedback to PLC via speed sensor and encoder.
 If anyone yarn breaks then yarn break sensor give signal to plc at that time machine will
stop.
 When desired length is reach machine will stop for changing beam.
 For safety purpose if emergency switch active machine will stop.

3.3 Required Instruments

In order to implement the project the following electrical devices are required:

Sl.N Component’s Name Required

o Quantity
1 PLC(LS Master K120S, K7M-DR40U) 1 Pc
2 HMI(Delta,DOP-B07S411) 1 Pc
3 Relay,24VDC 5 Pcs
4 Proximity Sensor 6 Pcs
5 Motor,12VDC 5 Pcs
6 DC Power Supply Unit 1 Pc
7 DC-DC Step Down Adjustable Power Supply Module 5A 2 Pcs
8 Photo Sensor Module 8 Pcs
9 Push Switch 3 Pcs
10 Emergency Switch 1 Pc
11 Communication cable PLC to PC, RS 232 1 Pc
12 Communication cable PLC to Touch Screen, RS232 1 Pc
13 Communication cable PC to Touch Screen 1 Pc
14 Connection Cable as required

3.4 Description of Project Related Components

The description of the used electrical components for the hardware implementation of the
project is stated below:

3.4.1 PROGRAMMABLE LOGIC CONTROLLER (PLC)

A programmable logic controller (PLC) is an industrial computer control system that

continuously monitors the state of input devices and makes decisions based upon a custom
program to control the state of output devices. A PLC consists of two basic sections i.e., the CPU
(Central Processing Unit) and the input/output interface system. During its operation, the CPU
completes three processes:

Step 1: It reads the input data from the field devices via input interface.

Step 2: It executes or performs the control program stored in the memory system.

Step 3: It writes the output devices via the output interface. These processes are known as
Scanning.

READ EXECUTE WRITE

SCAN
In this project, LS Master K120S, K7M-DR40U model is used for programming using ladder
logic programming language and the program has uploaded into a PLC processor via serial data
communication link.

3.4.2 Human Machine Interface (HMI)

Figure 3.1: LS Master K120S, K7M-DR40U PLC
The Human Machine Interface is the means through which an operator or user can communicate
with the system. The present status of the system is sent to the operator or user by means of a
graphical user interface (GUI). The operator or user can interact with the system by turning ON
or OFF various functions from the interface. In this project, I have used Delta, DOP-B07S411
HMI and the DOP- Soft is used to design the screen of the HMI that provides easy access and
control of system.

Figure 3.2: Delta, DOP-B07S411 HMI

3.4.3 Relay
A relay is an electrical switch that uses an electromagnet to move the switch from the OFF to ON
position instead of a person moving the switch. It takes a relatively small amount of power to
turn on a relay but the relay can control something that draws much more power. Ex: A relay is
used to control the air conditioner in your home. The AC unit probably runs off of 220VAC at
around 20A. That's 3520 Watts! The coil that controls the relay may only need a few watts to
pull the contacts together.

When current is passed through the coil it creates a magnetic field that pulls the switch closed.
Usually a spring will pull the switch open again once the power is removed from the coil. The
contacts are usually labeled Common (COM),
Figure NormallyRelay
3.3: Electrical Open (NO), and Normally Closed (NC).
The Normally Closed contact will be connected to the Common contact when no power is
applied to the coil. The Normally Open contact will be open when no power is applied to the
coil. When the coil is energized the Common is connected to the Normally Open contact and the
Normally Closed contact is left floating. Select a relay with a coil voltage and current that you
can control easily. Ex: If you want to turn on the AC unit with a 12VDC power supply get a
12VDC coil. Coils will be rated for either AC or DC operation.

3.4.4 Proximity Sensor

A proximity sensor is a non-contact sensing device that uses electromagnetic to sense the
presence of an object. They are well suited for industrial and harsh environment applications as
they feature rugged construction with longer service life, have higher temperature tolerances, and
their operation is not affected by liquids, oil or dust. Inductive proximity sensors are used to
detect metal targets while capacitive proximity sensors are used to detect plastic, liquid and
organic targets.

Figure 3.4: Proximity Sensor

3.4.5 DC Motor
A direct current or DC motor is a device that converts electrical energy into mechanical energy
or imparts motion. In this project, motor usually plays an important role to driving warping
beam, lifting and coupling/decoupling the warping beam. In general, motor operating with the
effect of conductor with current and the permanent magnetic field. The conductor with current
usually producing magnetic field that will react with the magnetic field produces by the
permanent magnet to make the motor rotate. DC motors are most easy for controlling. One DC
motor has two signals for its operation. Reversing the polarity of the power supply across it can
change the direction required. Speed can be varied by varying the voltage across motor.

Figure 3.5: DC Motor

3.4.6 DC Power Supply Unit
In this project, DC power supply use for control voltage of PLC, HMI and relay. Input voltage
220 VAC and output voltage 24 VDC.

Figure 3.6: DC Power Supply Unit

3.4.7 Photo Sensor Module

In this project, the photo sensor module group use as yarn break sensor to detect yarn is broken
or not.
 Figure 3.7: Photo Sensor Module

3.4.8 Communication Cables

To build up this project work need some communication cable like-
 PLC to PC communication cable for program upload and download to the PLC.
 HMI to PC communication cable for program upload and download to the HMI.
 HMI to PLC or PLC to HMI communication cable for data receive and transmit among
them.

Figure 3.8: Communication Cable between PLC and PC

 Figure 3.9: Communication Cable between HMI and PC

Figure 3.10: Communication Cable between HMI and PLC

3.5 Input and Output connection diagram of PLC

 Figure 3.11: Input and output connection diagram of PLC

Legend:
PB1=Stop switch. Yb1=Yarn break sensor 1
PB2=First speed switch. Yb2= Yarn break sensor 2
PB3=Second speed switch. Yb3= Yarn break sensor 3
S1=RPM count sensor. Yb4= Yarn break sensor 4
S2=Length count sensor. S3=Beam lifting up sensor.
S4=Beam lifting down sensor. S5=Beam coupling/decoupling left sensor
S6= Beam coupling/decoupling right sensor. R1=Beam coupling relay.
R2=Beam decoupling relay. R3=Beam lifting up relay.
R4=Beam lifting down relay. R5=Beam drive second speed relay.
R6= Beam drive first speed relay.

Figure 3.12: Motor control diagram

3.6 Ladder diagram of PLC
3.7 HMI Program brief description
 At first power up the system
 After power up the system, log in page will appear. Then put password 1111(Reference
Fig-3.13).
 After that home page will come. In this page PROCESS and PLC I/O STATUS button
available (Reference Fig-3.14).
 After click the PROCESS button, process page will appear. In this page Home,
Stop/Zero(0),First Speed(I),Second Speed(Ii),Beam Lift Up(↑),Beam Lift Down(↓),Beam
Coupling(→‖←),Beam Decoupling(↔),Yarn break sensor active button are available.
Also have Length setting, Length display, RPM display and Message display(Reference
Fig-3.15,3.16 and 3.17).
 After click the PLC I/O STATUS buttonmold I/O status page will open. Here can see plc
input and output active and inactive(Reference Fig-3.18).
Figure 3.13: Log In page of HMI

Figure 3.14: Home page of HMI

Figure 3.16: After Click Yarn break sensor active button

Figure 3.17: After Active Yarn break sensor

3.8 Operating procedure
 At first Power On
 Then Beam Place in machine (Reference fig-3.19).
Figure 3.18: I/O status of PLC
 Beam lift up (Reference fig-3.20).
 Beam Coupling(Reference fig-3.21).
 After Beam Coupling, beam lifting system need to go down
 After beam lifting system goes to down, beam ready to rotate
 To set the desired length and to active yarn break sensor
 Press the first speed button, then second speed button (if require) (Reference fig-3.22a
and fig-3.22b).
 During running if any yarn to break then machine will stop automatically
 If desired length reached machine will stop for beam unload.
Figure 3.19: Beam Place in machine

Figure 3.20: Beam lift up

Figure 3.21: Beam lift up

Figure 3.22(a): Machine running