A PROJECT REPORT ON

DYEING MACHINE CONTROL SYSTEM FOR VIBRONICS PRIVATE LIMITED

SUBMITTED BY
KAMBLE MANOJKUMAR SANTRAM MBA (2005-2007)

IN PARTIAL FULFILLMENT OF MASTERS DEGREE IN BUSINESS ADMINISTRATION

UNIVERSITY OF PUNE

THROUGH VISHWAKARMA INSTITUTE OF MANAGEMENT PUNE

Acknowledgement

Every project has a number of persons involved in it, some directly others indirectly. Everyone has contributed to its success; the critics who spur you into action with renewed enthusiasm and the supporters who steadfastly encourage you all through till the end. I would like to take this opportunity to

express my gratitude for all those who provided valuable criticism, appreciation and guidance to make this project a success. I thank Mr. Pramod Chavan my Training

Coordinator, Vibronics Pvt. Ltd. for the project, whose inspiration, whose sharing of anecdotes to exemplify the advice he would give, helped me see through this project swimmingly. I thank Dr. Vandana Gote my Project Guide for her guidance, motivation and attention. She was very much approachable with all my doubts! It was indeed a privilege to have done my project at Vibronics Private Limited. The learning experiences at Vibronics Private Limited are something that I would cherish for the rest of my life. Having worked in this corporation gives me the confidence and an outlook out of the box much needed before I take steps in the professional world.

Manojkumar Kamble Pune

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CONTENTS
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EXECUTIVE SUMMARY OBJECTIVE AND SCOPE COMPANY PROFILE EXISTING SYSTEM & NEED OF THE SYSTEM OPERATING ENVIRONMENT PROPOSED SYSTEM REQUIREMENT DETERMINATION TECHNIQUES SOFTWARE ENGINEERING PARADIGM WORKING OF DYEING MACHINE CONTROLLER RUNTIME FORMS TESTING PROCEDURE & IMPLEMENTATION PHASES LIMITATIONS PROPOSED ENHANCEMENT CONCLUSION BIBLIOGRAPHY

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B. Ltd. Pune during the academic year 2005-2007 for the partial fulfillment of MBA from our guidance. Sharad Joshi Director VIM Dr.A. Kamble Manojkumar S. Vandana Gote Project Guide 4 . a student of M. Dr.CERTIFICATE This is certify that Mr. (Systems) from Vishwakarma Institute of Management Pune has successfully completed his project work on Dyeing Machine Control System at Vibronics Pvt.

Microcontroller. we also manufacture a set of detergents that can pragmatically handle our ultrasound cleaners. The company has been a catering to the engineering industry with its vast range of technically sound products. Being a student of system apart from my software work I also got much more familiar & interesting part of Embedded System and various dedicated system which I was not familiar or worked on it before.backed by efficient person aliased after Sales & Services. Embedded System. Vibronics Private Limited has been a forerunner in the field of ultrasonic devices. Apart from having a vast range of ultrasonic equipments. ultrasonic processors. ultrasonic cleaning systems etc. The Dyeing Machine Controller has a combination of three different Technologies viz. ultrasonic cleaning equipment. flaw detectors. With the commitment of excellence backed by intensive R & D. Our top quality and accurate devices are a result of the brainstorming efforts of technocrats. With a branch network throughout India. the Company serving the engineering industry for thirty-three years. ultrasonic cleaners. 5 . Vibronics offers the finest in Ultrasonic Cleaning Systems and other products. Project Title:- Dyeing Machine Control System. Software Visual Basic & Electronic Equipments. Vibronics Private Limited is a Mumbai (India) based leading manufacturer and exporter of ultrasonic cleaning machine. ultrasonic cleaning solution.EXECUTIVE SUMMARY Introduction:- Vibronics.

Objectives:To enhance the performance of the Dyeing machine System in the textile industries. Integrity. To increase the reliability of the Dyeing machine system. The Automated Dyeing Machine Microcontroller also helps to control different temperature levels which are hard to handle by person manually and also the different water level along with the various Recipe s . It also helps to make a impact of the company on Global World. Consistency. The Various Features this Automated Dyeing Machine Controller consists will help the Textiles Company to think on various color combination which can be applied as per the customer need within a span of period. to avoid this problem we developed this Automated System to overcome this problem.. To reduce the manpower this is to handle the dyeing machines. One of the important role this Dyeing Machine Microcontroller plays is that it help to save the manpower of Thirty Machine in a single phase of it s work. 6 . Cost control. Scope:- The textile industry nowadays don t have any automated system developed on which the Company can be reliable of what exactly the customer is in need of.

Some Myths and facts . ultrasonic cleaning equipment. we also manufacture a set of detergents that can pragmatically handle our ultrasound cleaners. company has technically collaboration with Hansaonic Pte.backed by efficient person aliased after Sales & Services. There are numerous misconceptions related with ultrasonic cleaning 7 . The PC based industrial Automation System. Apart from having a vast range of ultrasonic equipments.e. ultrasonic cleaning systems etc. The company has been a catering to the engineering industry with its vast range of technically sound products. ultrasonic cleaners. ultrasonic processors.Company Profile:Vibronics. Vibronics Private Limited is a Mumbai (India) based leading manufacturer and exporter of ultrasonic cleaning machine. Our top quality and accurate devices are a result of the brainstorming efforts of technocrats. Vobronics Private Limited has two main achievements in the current days i. flaw detectors. and along with the ultrasonic products the company has decided to provide the service in the industrial automation. the Company serving the engineering industry for thirtythree years. Based South Korea. ultrasonic cleaning solution. With the commitment of excellence backed by intensive R & D. Vibronics offers the finest in Ultrasonic Cleaning Systems and other products. With a branch network throughout India. Vibronics Private Limited has been a forerunner in the field of ultrasonic devices.

saponifiers etc. the best option They are the perfect means of judging a cleaner Factors in Cavitation The numerous factors that are responsible for cavitation are as follows: Frequency . pH buffers. inhibitors. Physical properties of cleaning agent .higher the frequency the faster the cavitation and vice-versa. Its key stages include: - 8 .these include attributes like: · Viscosity · Vapor pressure · Temperature · Density The ultrasonic cleaning process Ultrasonic cleaning mechanism is a an effect created by the action of sound waves at high frequency. It utilizes the synergetic effects and offers multiple degrees of freedom in concentration and blending. they include: Ø The louder the cleaner the better Poor insulation or a low frequency system maybe the main cause of loudness.processes.. Ø The quiter the cleaner the better Higher frequency operation and good insulation may lead to quitness. introduced into liquid cleaning medium. The process consists of four major components like: · Transducer · Generator · Tank · Cleaning solution Aqueous Cleaning This cleaning uses water as its main solvent and has synthetic detergents and surfacants combined with special addictives such as builders. Ø Visual observation or ultrasonic power meter.

· Cleaning difficulty · Rising · Floor space · Drying · Material compatibility · Water · Energy consumption Wastewater disposal .· Washing · Rinsing · Drying · Wastewater disposal The merits and Demerits ADVANTAGES Aqueous cleaning system has several advantages over organic solvent cleaning. however.in some instances . the use of aqueous cleaning may require wastewater treatment prior to discharge. there are also some disadvantages. 9 . · Safety · Cleaning · Inorganic or polar soils · Oil and grease removal · Multiple cleaning mechanism · Ultrasonics applicability · Chemical cost DISADVANTAGES Depending upon the specific cleaning application.

Industries Served Rayon Industries Poly Film Industries Polyester Industry Gear Industry Wire Industry Watch Industry Pump Industry Automobile Industry Compressor Industry Machine Tool Industry Electroplating Industry Brass Art Ware Industry Ball Pen Industry Semiconductor Industry Picture Tube Industry Electronic Component Industry PCB Manufacturing Industry Hospital & Pharmacy Industry List Of Competitors: AMICO INDUSTRIES PVT LTD ENRTECH PVT LTD RADIX PVT LTD 10 .

Tel : (044) 4404114.com For further information contact your Branch/Office.500003. Tel : (079) 6562466.net.in | vibronics@iname. 7867652. Maharashtra.19. Yusuf Sarai. TTC Industrial Area. Lalit complex. Room No. Secundrabad . Navrangpura.D. Fax : (044) 4915985 KOLKATTA OFFICE : M/S. Tel : (040) 7819928. ENGR. THIRUVALLUVAR NAGAR. Hindustan Trade Agency.110016. Rabale Navi Mumbai. Near Jain Temple. AHMEDABAD OFFICE : AARKEY Associates. R. Mumbai . Delhi .400 701.700 001 11 . Fax : (079) 6562466 CHENNAI OFFICE : RESID.. (Martin Burn House) 5th Floor. CHENNAI-600041. Akolawala Mustufa W-400. Tel : (011) 6525149.bom@mtnl. Mr. S. MIDC. Fax : (011) 6866730. 1st floor.N Mukherjee Road. 6966186 SECUNDRABAD OFFICE : Srinivasa Enterprises. Green park. Ahamedabad.BRANCHES AND OFFICES Vibronics Pvt. Kolkatta . 126/A. 6966186. 6866730.road. TNHB FlATS. THIRUVANMIYUR. 7847546 Fax : (040) 7847546. DELHI OFFICE : 40. Ltd. Tirumala complex. 7849910.380009. 1. India Tel : +(91)-(22)-27690440/27690593/27690636 Fax : +(91)-(22)-27690440/27690593/27690636 Email : vpl. -M/10/S-4. .

Opp.Telefax : 2107091/ 92/ 6524 PUNE OFFICE : G-203.in.bom@bol.mcpai d@indiamart. Guru Ganesh Nagar. Tele : (020) 528 2708. Paud Road.com 12 . Ltd. Pune . Mail Through vibronicsindia.net. Maharashtra.vibronics@iname.com. Vrindhavan Heights.com.com?subject=Vibronics Pvt. Email : mailto:info@vibronics.vpl.411 029.

. ceramic. alloys etc. Ø Rigorous cleaning of intricate parts that are normally inaccessible 13 . This intense disturbance in the liquid contained in the tank will cause to form and collapse of millions of microscopic cavities or voids known as cavitations. descaling etc.. safe and compact procedure Ø Specially designed for rapid and thorough cleaning of small and large components and assemblies Ø Results in efficient cleaning of metal. When these cavities collapse or implode they release tremendous energy and produce an intense local scrubbing action on the objects immersed in the liquid. plastic. These piezo electric transducers convert electrical oscillations to corresponding mechanical vibrations and cause the tank bottom to vibrate. features Ø Complements industrial cleaning process Ø Provides high intensity cleaning action with optimum efficiency Ø Economical. resulting in intense agitation of the liquid contained in the tank. Ø Greater efficiency with high intensity cleaning. for cleaning. for derusting. Ø Usable with high temperature detergents.PRODUCT RANGE:Ultrasonic Cleaning System :- ULTRASONIC CLEANING the process Electrical Energy from a transistorized oscillator circuit is fed to the transducers. Ultrasonic cleaning systems. decarbonising.

Fume extractions and chilling plant facilities are optional. The system is ideal for degreasing. Technical Specification Tank Material : Stainless steel/mild steel rubber. Continuous filtration. decarbonising and other cleaning requirements of automobile engineering. descaling. water separation. and automatic / semi-automatic material transfer system are the features of the system. automatic distillation. electrical and electronics and textile industries. onwards Cleaning technique : Ultrasonic and/or jet spray Frequency : 25 KHz to 43 KHz Ultrasonic power : 120 watt to 25 kw Mounting : Epoxy bonded/wielded/immersible module Transducers : Piezo electric-sandwich mode 14 . ultrasonic and vapor cleaning / dying.precleaning. recirculation. Lined fibre glass reinforced Tank Capacity : 3 ltr. The cleaning system is custom built on turnkey basis. derusting.Fig 1: Ultrasonic Cleaning System MULTISTAGE CLEANING SYSTEMS:- The Multistage Cleaning systems normally have 3 stages .

All models of this series incorporate boiling sump for generation of vapours and removal of soil. Per min. Vapor degreasers can be alternatively used as solvent recovery plant with correct selection of heat loads and valves.Multistage Cleaning System SINGLE OR MULTISTAGE VAPOUR DEGREASERS WITH SOLVENT RECOVERY FACILITY Vapor degreasers are fully integrated efficient degreasing systems. To 20 ltr. Salient Features The prime features of the multistage vapor degreasers are as follows:Ø Effective condensation and water separation Ø Heat insulation 15 . built-in stainless steel with efficient condensation and water separation facility. Fig :. grease.Jet Pressure : 30 to 600 PSI Liquid flow : 2 ltr. They are rugged. wax and other solvent soluble soils from intricated cavities.

A plug in battery charger permits the battery to be charges without removal from the main unit. Field operation specials Models available: FD 301 M.SINGLE OR MULTISTAGE VAPOUR DEGREASERS WITH SOLVENT RECOVERY FACILITY Ultrasonic Flaw Detectors 1.Ø Digital controllers Ø Vigorous vapour generation chambers Ø Low/high level central with alarm Ø Dust and vermin proof control panel Fig :. Both models are powered by rechargeable batteries housed inside the main units. 16 . FD 301 MP. FD 401 MP An ideal instrument for filed operation. it provides precise quantitative evaluations with the simplest of controls that anyone can handle.

Provision is made for a water tank to enable a constant water supply for probe coupling.100 cms with a multiplying factor of 5 Time base linearity PRF Better than 1% Variable from 1 KHz to 125 Hz interlinked with range Display Operating temperature 70 x 55 mm 40C to 60C 2. 17 . The unit employs five double probes. The whole unit is made to RDSO'S specifications and has its approval.5. FD 301 MP. two of 70° and 37° forward backward type and one special 70° double probe. FD 401 MP Frequency range Vertical Linearity Gain Gain control 0. Vibronics rail tester Model: FD 301 R It is used for testing of rails during manufacture and after for fatigue cracks.5 MHz to 12 MHz + 2% 140 dB 80 dB in Steps of 2 dB + 6 dB stepless Depth range Delay Ranges provided Upto 5 mtrs in steel 3 mtrs of steel 1.Technical specifications for FD 301 M.10.50.

using standard calibration blocks. Probe cables Standard BNC to BNC available ex-stock for length from 2 meters onwards. Vibronics plate tester The flaw detector is mounted on a trolley with universal movement. The trolley is housed with 4 MHz double crystal probe and built-in water tank to ensure continuous couplant for the probe. Calibration blocks The instruments' performance can be checked and adjusted regularly and easily. Batteries Reliable long life cycle rechargeable batteries for use in all portable instruments. 18 . Special cables like BNC lemo etc. 5. Vibronics accessories Carrying case Gives added protection to instruments at all times. supplied on request. Available in 5 hrs or 8hrs chargeable time. The equipment is totally battery operated.3. Additional angular probe and digital attachment are optional.

Ultrasonic Flaw Detectors 19 .Fig :.

shock waves at sound frequency cause great alterations of pressure those results in formation of large masses of vacuous bubbles. round the point. biological specimens. high instantaneous temperature and micro streaming of the liquid. This equipment is basically used for research and small volume production. It is attached to a pair of lead Zirconate titanate transducer elements. such as:· Pressure mixing · Magnetic stirring · Colloid mill Cell disruption Ultrasonic processors cause ultrasonic "cavitation". Product description It comprises of an electronic generator that generate 120 to 250 watts of average electrical energy. giving rise to intense local shock waves. The 2 models available with us are: · Model VPL-P1 of power 120 watts & dia ½" · Model VPL-P2 of power 250 watts & dia 1" 20 . The transformer or velocity horn amplifies the small vibrations. During caviatation. dyes etc. Some of its applications include: · Cell disruption · Enzyme extraction · Deaeration Advantage It has a great advantage over the traditional ones. Then they implode and disintegrate. These bubbles grow until a critical stage is reached.Ultrasonic Processors It is a vivid and multi-dimensional instrument that covers a variety of samples such as aerated liquids.

Cleaning Chemicals New Range With the objective of diversifying it's field of production and providing effective cleaning chemicals and industrial detergent. itching (5) Indigestion (6) Hair loss.Ultrasonic Processors New Range. Cleaning Detergent After a lot of R&D and efforts. economy 21 . we have struck the right note the form of these cleaning detergent. Vibronics Private Limited has come out with a new range of detergents.Ultrasonic Processor medical cures Our product can offer cure for the following medical problems(1) Blood sugar/Diabetes (2) Acidity/Gas (3) Cleaning of blood (4) Pimples. skin irritation. Fig:. Their salient features include easy availability.

These materials determine the acidic. alkaline or neutral nature of these detergents.and most importantly. An exhaustive list of the ingredients of these chemicals is given below. efficiency. Ingredients : » Degreasing Agents Vibrosol GDA Vibrosol GDC Vibrosol GDF Vibrosol GDH Vibrosol DCB Vibrosol DRH » Descaling Agents Vibrosol DRD » Descaling Agents Vibrosol DSA Vibrosol DSD » Decarbonising Agents Vibrosol DCB » Lancquer/Varnish/Paint remover Vibrosol DLP » Cleaning & Brightening chemical Vibrosol MBA Vibrosol BCA » Dewatering chemical Vibrosol RPD 22 .

we are there for your service. Whatever the problem and whenever it arises.Our technical team is always available for your assistance. The chemical wing is ready to solve your cleaning problems. Fig :.cleaning chemicals Fig:.industrial detergent 23 .

In this System.Existing System and Need for the System Existing System Dyeing Machine Handling in Textile Industries: In the existing system when a worker or end user work on a single machine & he handles a single machine manually it takes a lot of time to apply different color shading in the Dyeing machine. The theme here is wastage of manpower per machine as well as the training for the each worker who handles the machine. New System In the new system we provide Dyeing Machines Control System to textile industries to automate their Dyeing machines to increase the performance and reduce the manpower as well as control the cost factor. The worker who works on the machine has technically strong knowledge about handling a single machine at a time and he is not capable at the same time to apply the different colors to different fabrics at the same time as per the Customer requirements. This system provide to store the different recipes on a micro. means to increase the reliability of the worker. In the existing system there are so many drawbacks which are non recoverable for any textile industry. one man can handle the 30 dyeing machines at a time and gives different color shades to the fabrics as per the Customer requirement. 24 . One important drawback of the existing system from the Organization point of view is that every machine requires a separate worker and special training to handle the same machine.controller chip and reuse it when required.

0 as a front end and MS. The following are the Recommended hardware configuration work without any problem in a long run. It incorporates SQL & provides a graphical user interface (GUI).485 Protocol.485.Access. LPC 2141. Operating System The proposed system can work on under Windows 9x.controller Protocol : Pentium 2. : 20 GB. : 20 GB. Windows NT 4. Embedded System. & RS. Processor RAM Hard Disk Micro.0. : 256 MB. Windows 2000 and Windows XP as a operating System. : RS.8 MHz.8MHz. Hardware Configuration The following is the minimum Hardware configuration required Processor RAM Hard Disk Micro.Operating Environment Hardware and Software The proposed system has been developed using Visual Basic 6. : LPC 2141.e. 25 . Micro Controller i. : 128 MB. : LPC 2141. : RS.controller Protocol : Pentium III 2.485.

A Facility provided for storing the color combinations by the use of Recipe Storage System within the Dyeing Machine to avoid repetition of work on the same color combination of the fabrics to be applied. Integrity. Cost control.Proposed System Objectives to be fulfilled To enhance the performance of the Dyeing machine System in the textile industries. Pressure of the Dyeing Machine. User Requirement To Maintain the Tank levels of Dyeing Plant in Textile Industry. Consistency. To reduce the manpower this is to handle the dyeing machines. To Reduce the Manpower to maintain the Cost Factor of the company. To maintain different Temperature. 26 . To increase the reliability of the Dyeing machine system. Consistency & Reliable System. Requirement of all the details every day regarding each Dyeing Machine and the Recipe it worked on. To maintain the different Water & Color Flow.

data flow analysis. they are not merely computer studies. 27 . The determination of requirements thus entails studying the existing system and collecting details about it to fins out what this requirement are. controlling a business activity. Requirement Investigation:- Study and documentation of current system. and Requirement Anticipation Foreseeing systems characteristic based on previous experience. A requirement is the feature that must be included in a new system. decision analysis. requirement investigation. It may include a way of capturing or processing data.Requirement Determination Techniques and system analysis method employed. Systems studies result in evaluation of how current methods are working and whether adjustments are necessary or possible. anticipation. or supporting management. May also introduce focus. producing information. Activities in Requirement Determination It is helpful to view requirement determination through the three major activities of requirements requirement specification. These studies consider both manual and computer methods as we shall see. using fact finding techniques. What is Requirement Determination? Requirement Determination involves studying the current business system to find out how it works and where improvements should be made. May cause the analyst to investigate areas and issues that could otherwise overlook.

SOFTWARE ENGINEERING PARADIGM [DATA FLOW DIAGRAMS & FLOW CHARTS] 28 .

Data Flow Diagram of Dyeing Machine Control System End User Machine Network (1-30) Machine Selection Machine Utilities Machine Recipe Machine Comm n OEM Parameter Data History Print Create New Recipe List Of Recipe Machine Configuration Machine Parameter Machine Timers Recipe s Data History OEM Properties Micro Controller Dyeing Machine 29 .

REVERSE MVAT8 PRESSURI.REVERSAL Z1 A A A BB A M CA S CA N CA CT A C CA CO A CU A D DA P CA V CA EE A Q CA W CA F A CR A CX A G A H MVAT9 DEPRESSU RI.MANUAL Select Tank MVAT ADD TANK STOCK TANK Select Process MVAT1 FILLING MVAT2 RINSING MVAT3 HT DRAIN MVAT4 OV. Y A Select Process ADD TANK1 MAIN VAT ADD TANK2 INJECTION ADD TANK3 DOSING ADD TANK4 TANK CLEAN ADD TANK5 MIX & HEAT ADD TANK6 FILL Z A Select Process STOCK TANK1 FILL STOCK TANK2 MIX HEAT STOCK TANK3 MAIN VAT STOCK TANK4 MAIN STOCK STOCK TANK5 TANK CLEAN STOCK TANK6 P. MVAT10 HEAT&RU N I J MVAT11 SQUEEZE K J Fig :. MVAT5 LT DRAIN MVAT6 OPEN MVAT7 P.Data Flow Diagram of working of the MIMIC Control Panel MVAT12 SHOCK RINSE 30 .F. CIRC.F.

FLOW CHARTS OF DIFFERENT PROCESSES 1) MVAT FILLING 2) MVAT RINSING A B HOT WATER LEVEL COLD WITH RINSING COOLIN G HOT WITHOUT COOLING ENTER LEVEL ENTER TARG ET RINSE TYPE HOT/CO COLD ENTER RINSE PRESS START P/B TIME. PRESS Y 3) MVAT HT DRAIN C 4) MVAT OVERFLOW CIRCULATION D EFFLUENT DRAIN DRAIN TYPE HT DRAIN ENTER TIME PRESS START P/B PRESS START P/B Y Y 31 . Y . ENTER TARG ET ENTER CIR.

TIME H ENTER PRESSURE LIMIT ENTER REVERS E TIME PRESS START P/B ENTER PUMP SPEED ENTER PRESSUR CONTRL.5) MVAT LT DRAIN 6) MVAT PREPARE TO OPEN E F ENTER LEVEL PRESS START P/B PRESS START P/B Y Y 7) MVAT PUMP FLOW REVERSAL 8) MVAT PRESSURISATION G ENTER FWRD. ENTER FLOW CONTRL Y PRESS START P/B Y 32 .

OF CYCLES ENTER TIME PRESS START P/B PRESS START P/B Y Y 33 .9) MVAT DEPRESSURISATION 10) MVAT HEAT &RUN J I ENTER TEMP ENTER RESSURE LIMIT ENTER GRADIE NT PRESS START P/B ENTER HOLD TIME Y PRESS Y 11) MVAT SQUEEZE 12) MVAT SHOCK RINSE L K ENTER NO.

PRESS START P/B Z 34 . ENTER OPEN TIME PRESS START P/B ENTER QUANT-ITY ENTER CLOSE TIME Z ENTER TIME.HOT 1) AD1 MAIN TO ADD TANK 2) AD INJECTION M N ENTER LEVEL PRESS START P/B PRESS START P/B Z Z 3) AD DOSING O 4) AD CLEAN PROBE=1 ADD LEVEL PROBE HOT PROBE=0 P ENTER CURVE NO.

5) AD MIX & HEAT 6) AD ADD FILL Q R ENTER MIX VALUE ENTER LEVEL ENTER TIME ENTER TEMP PRESS START P/B PRESS START P/B Z Z 1) ST FILL 2) ST MIX & HEAT S T HOT WATER LEVEL HOT/COLD COLD ENTER MIX VALUE ENTER TIME ENTER LEVEL ENTER TEMP PRESS START P/B PRESS START P/B Z1 Z1 35 .

FWD.3) ST MAIN TO STOCK TANK 4) ST STOCK TO MAIN VAT U V ENTER LEVEL ENTER LEVEL PRESS START P/B PRESS START P/B Z1 Z1 5) STOCK TANK CLEAN 6) ST PUMP FLOW REVERSAL X ENTER FWRD. TIME w ENTER REVERS E TIME PRESS START P/B ENTER FLOW ONTROL Z1 ENTER DIFF. ENTER FLOW CONTRO L PRESS START P/B Z1 36 . PR.

Micro Controller. End User.Working Of Dying Machine Controller This is the diagrammatic representation of the working of the Dying machine Controller it is divided into three different parts 1. 37 . Dyeing Machine. 2. 3. 1) End User:This part includes all the input from the user manually regarding the instructions to the machine or the expected work from the machine. It also sends the data through this frame to Micro Controller the form of RS-485 protocol and the language used is ASCII Hex.

The data acquired by the microcontroller card is transferred to PC using RS485 protocol developed by Photon Techniques.2) Micro Controller:Micro Controller plays an intermediate role between the End user and the Dyeing Machine. Pressure 3. 3) Dyeing Machine:It follows the instructions which it receives through the Micro Controller and responds to whatever the input given and generates the appropriate results and sends the acknowledgement to the end user. Energy Consumed 5. It receives the frame from end user and read the particular machine address which is stored in frame and sends this frame to particular machine and it also receives the frame from machine and sends it to End User. Temperature 2. The function of microcontroller card is to acquire machine related parameters. There will be total 29 machines. Development of multidrop RS485 interface. Production Rate 4. Physical Parameters: 1. The multidrop RS485 protocol is to be designed and developed to establish communication between microcontroller cards and PC. Individual machine has microcontroller card connected to PC over RS485 bus. Machine On/Off status 38 . The nature of physical parameters and respective sensor output as well as data format requirements of acquired data provided by BTRA in the initial stages.

necessary modifications were done. ASCII Hex format and Frame structure are used for transmission of data over the bus. Development of software to acquire data of physical parameters.Sensors to sense the physical parameters Physical Parameters Temperature Pressure Production Rate Energy Consumed Machine On/Off Status Sensor Output Type Analog 0 to 5 V Analog 0 to 5 V Digital 116 pulses / sec Digital 0. Here 29 microcontroller cards and PC are sharing the same bus. 1. Routines are written to acquire the data as per the format In multidrop system. To avoid corruption of data due to data collision and misinterpretation of data. hence designing of test jig for simulation of physical parameters is essential. multiple devices are connected over 2 wires. Jig is designed by Photon Techniques as per the specification of physical parameters provided by BTRA. Jig designed was confirmed to BTRA and with the consultation.3 Hz Digital 100 Hz Physical Parameter Temperature Pressure Production Rate Energy Consumed Machine On/Off Status Digital Value 10 Bits 10 Bits 16 Bits 8 Bits 1 Bit Bytes Required 2 Bytes 2 Bytes 2 Bytes 1 Byte 1 Byte The real time demonstration of RS485 protocol requires real time acquisition of data. 39 .

By using this format each byte is represented by pair of ASCII codes that represents the bytes 2 hex characters.Frame Structure of the RS-485 Protocol Whenever data is transmitted on serial cable.In multidrop system any device can communicate with any device. data and commands over RS485 bus. To avoid this. The frame will contain Start of frame Device ID (Address of receiving device) Source ID (Address of Transmitting device) Function code Data count (Count of data bytes transmitted) Data Check Sum (Check sum of data bytes) 40 . To avoid misinterpretation of data transmitted between master and slave device. If two devices are transmitting data at same time then there will be collision of data. Data format over RS485 bus ASCII Hex format is used for serial transmission of data over RS485 bus. master/slave configuration is used. Start of Device frame ID Source ID Functio n Code Data Count Data Check Sum End of NULL frame \0 Fig: . it will be transmitted in frame format only. ASCII Hex format and frame structure is used. commands and actual data. There will be communication only between master and slave and not between two slave. This format represents any value between 0 to 255 using only ASCII codes 30H to 39H (for 0 through 9) and 41H to 46H (for A through F) Frame design to transmit address. PC will act as master and all microcontroller cards will act as slave. To identify the slaves. The frame is designed to do discrimination of serial data as address. we have given the addresses ranging from 1 to 29 to each slave and higher end address is given to masters Only master can generate request for transmission of data from slave devices.

End of frame NULL (Termination of frame) Data transmitted in frame has given a meaning only inside the function. g. We have designed a function code to give proper meaning to data for e. Function Code 01 is used for identification of slave (microcontroller cards) Function Code 02 is used for RTC programming of slave (microcontroller cards) Function Code 03 is used for Transmission of acquired data from slave to master (microcontroller cards to PC). 41 .

Scientific Diagram of Dyeing Plant (1) Fig:-Scientific Diagram of Dyeing Plant (1) 42 .

digital panel meter values. push button indicators. MIMIC Control Panel Tester:MIMIC control panel is designed to show the current working status of the one particular machine. status indicators on the user screen. buzzer etc. Add VAT. 43 . It is designed to check the tank levels. and Stock Tank.The Overview of the Dyeing machine Plant Fig: . MIMIC control panel is directly communicate with the machine through micro.controller LPC 2141 and receive the reports of the machine.Dalal Dyeing Plant (Final Screen) It visualizes the entire working of this plant including all the aspects right from Main VAT Tank.

Form: MIMIC Control Panel Tester (Before Working) 44 .

Form: MIMIC Control Panel Tester (After Working) The MIMIC control panel is divided into six frames i. Tank levels.e. Buzzer. DPM. Status Indicator. Message Number. 45 . Push Button Indicators.

To show the level of the mixture of color in the Stock Tank. The conditions may be Vice-Versa.First 3 DPM shows the values of Temperature. Stock Tank Level: . Stock Tank: .Tank Levels :- Main Vat level: . Status Indicators:These LED s are placed on different pipes to indicate whether the flow of water is through the pipes then & then only these LED s will glow. It also plays important role to show the different status of water flow which helps in our entire project. 46 .5th DPM to show the temperature of stock tank. Add Vat and Stock Tanks. Add Vat: .4th DPM to show the Temperature of the Add Vat Tank. There are 48 LED s on the user screen.To show the level of the mixture of color in the Add Vat Tank. Pressure and Hold timer of the Main vat Tank. DPM (Digital Panel Meter):- To show the current numerical values of the Main Vat. they are follows. 6th & 7th DPM to Show the flow of water level and turbo meter. Main Vat: . There are 7 DPM s on the MIMIC control Panel. Add Vat Level: .To show the level of the mixture of color in Main Vat Tank.

Turbo Pump 9. VENT 6. Stock Tank Feed (Hot) 33. Stop Tank Drain. Pressure 12.1. Cooling 8. ADD Tank Drain. Low Temperature 19. Outside In 4. Direct Fed Water (Cold) 30. 28. Injector Pump. Throttle 13. 31. Stock Tank Transfer 27. Direct Stream. 25. Effluent 21 Pressure Extractions 22. Heating 7. Supply to Back Cooler 14. Direct Fed Water (Hot) 29. Stock Tank Spray. Back Cooler isolating 15. 47 . Air 11. ADD Tank Transfer 24. Add Tank Spray 16. Stock Tank Feed (Cold) 34. ADD Tank Transfer (Pump) 26. 23. Rising 2. High Temperature. Stock Tank Heating. 32. 10. Pressure Control 5. Stock Tank Stirrer. 20. Inside Out 3. Drain 18. Add Tank Back Transfer 17.

Buzzer: - This Buzzer plays an important role which is used by the machine handler to indicate if any problem occurred. Message Number: - Whenever a problem is occurred Machine Sends a message to end user which signifies the machine in the network is having problem.Push Button Indicators: - The total numbers of push button indicators are 24 in number which indicates different tools which are used for manual working. 48 .

RUNTIME FORMS 49 .

Welcome Screen This form is the first form which the user will see on the screen. 50 . By clicking on the Enter Button he can proceed to Machine selection Form.1) The Welcome screen Of Dyeing machine Controller Form1:.

2) Machine Selection Form. Then Click on the Proceed Command Button 51 . Form2:. The end user can select any machine from the 32 machines by just selecting the particular no of the machine from the Drop down List.Machine Selection This form provides the selection of machine on which the end user wants to perform the required instructions or Work.

Print:- These are the various utilities which the End user can select and perform various action on that particular machine. The total numbers of utilities are six which are:1. Machine Recipe:2. 52 . Data History:5. Machine Communication:3.Utility Selection Form Once you select the machine number then the utilities that are present on the screen of the particular machine. Run Mode:6.3) Utility Selection Form:- Form3:. DEM Parameter:4.

Recipe Name. then it also necessary to enter Supervisor ID which signifies the Authenticated End user Name.Machine Recipe 4) Recipe Information :- Form4:. 2. 53 . The two Different Panels are 1.Recipe Information This Form Shows the First Utility Recipe Information which displays the machine number which you have selected to perform actions. Description and Recipe Number. Create New Recipe:When a Authenticated Supervisor want to prepare a new recipe then he can enter mandatory fields i. List of Recipe:The List of Recipe s shows all the present list of Recipes of the particular machine of the Authenticated Supervisor ID.e.

There are three subdivisions in this tools based on the different processes viz. Tools 2. Recipe Tools : It is an the set of processes which operates the operations in the all three Tanks of Dyeing machine to perform the recipe. User Authentication 3.5) Actual Dyeing Recipe:- Form5:. 54 .Dyeing Recipe When a user is need of creating a new recipe this form plays a vital role and he can perform all the required actions. 1. This Form is the main form which is divided into three different and important parts. They are as follows.

It performs the Prepare To Open The Main vat Tank. It perform the Rinsing of Water in The Main Vat Tank It performs the Squeezing Operation In the Main Vat Tank. Main VAT 2. Processes Filling Heat and Run HT Drain LT Drain MV Circulation Prepare to Open Pressurization Pump Flow Reversal Rinsing Squeezing MV Steaming Icon Description To perform the filling operation to the Main Vat Tank. Main VAT:There are twelve processes which is commonly used to perform the Dyeing Machine operations for Main VAT. It performs the HT Darin operation in the Main Vat Tank. Add Tank 3. It performs the Main Vat Circulation operation. 55 . It performs the Pressurization operation In the Main Vat tank. Stock Tank 4.1. Common Tank 1. It performs the Pump Flow Reversal operation in the Main Vat Tank. It performs the LT Darin operation in the Main Vat Tank. It perform the Heat and Run operation in the Main vat Tank. It performs the Main Vat Steaming.

Machine Number 56 . 3. It performs the Dosing operation in the Add Tank. It performs the Heat and Run operation in the Stock Tank. User Authentication :This Part consist of 1. Add Vat Tank Processes Filling Heat and Run Dosing Injection MV To Add Tank Cleaning Icon Description To perform the filling operation to the Add Vat Tank. It performs the transfer mixture MV to Stock operation. It performs the Cleaning operation in the Stock Tank. Supervisor Id 2. It performs the Injection operation in the Add Tank. It performs the Heat and Run operation in the Add Tank. Stock Tank:Processes Filling Heat and Run MV To Stock Stock To MV Cleaning Icon Description To perform the filling operation to the Stock Tank.2. It perform the operation of the transfer the Mixture from Add Vat to Main Vat Tank It performs the Cleaning operation in the Add Tank. It performs the transfer mixture Stock to MV operation.

3. it allows the end user to select the particular tool from the different processes and perform the required action on it as there are shown that the different Processes which starts with Main processes along with next Six Process which the end user can use to specify the action on that particular machine. Recipe Name 4. 57 . then he can save and use on different machines. Recipe Number. And End user wants to save this recipe to perform same recipe on different machines. Recipe Mixture :It is a consist of mixture of one recipe and steps to perform that processes.

Processing Properties. This form shows the properties of the particular process whose parameters the end user can manually change by selecting the drop down list and then clicking the OK command button to apply the properties to the process. 58 .6) Processing Properties:- Form6 :.

Data History 59 .Machine Communication This Form Displays the Second Utility i.7) Communication With Dyeing Machine:- Form7:. Recipe 2.e. Machine Communication it consists of:- 1. OEM Parameters 3.

As 60 .OEM Parameters 8) Selection Of OEM Parameters:- Form8: Selection Of OEM Parameters After Selecting the OEM parameters it will make the authentication request to the end user in response the user should specify the required details ..

It is used to check the person is authorized person or not to see or to handle the Machine Parameters.User Authentication Form This form helps the End User to enter his security details. Machine Configuration and Machine Timers because these fields are main to perform the machines.9) User Authentication Form:- Form9:. 61 .

10) OEM Parameters:- Form 10: -OEM Parameters After entering the security check the user is redirected to thus form which consists of the actual OEM Parameters as 1. 62 . Machine Timers 3. Machine Configurations All these can be manually changes or set by the end user as per his requirement. Machine Parameters 2.

Min Value 4.11) Machine Parameters Details :- Form11:. Max Value It is also provided with a Save Command Button which helps to save the details of the particular or the selected machine every day. 63 . Default value 5.Machine Parameters Details After selecting the first OEM parameters i. Units 3. Machine Parameters the table of machine details is displayed as shown above it consists the detail information regarding the performance of whole day which also help the end user to keep track of daily work done by it. Machine Constant 2.e. The various fields in this table are 1.

64 . It helps to set the timer or the span of time in which we want to complete particular.12) Machine Timers:- Form 12:. In single line we can call it as setting a timer to complete particular work in a given span of period specified by the user.Machine Timers The second parameter of OEM is this Machine Timers It also displays the overall details of the Machine in tabular format.

65 .Machine Configuration The Third Parameter of the OEM is Machine Configuration which allows the End User to perform the processes on the particular machine or not.13) Machine Configuration:- Form 13:. Here there are two options specified click on the appropriate to perform or not to as per the Machine Requirement.

Along with the progress bar which signifies the process time completed.Form Printing This Form Displays the two option of printing the recipe or the print history regarding the recipe. 66 .14) Form Printing :- Form14:.

And it also gives date & time of executed recipe on a particular Machine.15) List Recipes:- Form 15: List Recipes This Form displays all the list of the Saved recipes on the particular Machines and Super Visor ID that are authenticated to that particular machine. 67 .

17) Processes within the Recipe:- Form 16: Processes within the Recipe This form displays all the processes within the executed recipe but only after the selection of the particular recipe. Recipe Starting Time. It also gives the details of processing time required by each process on each machine. Recipe Ending time on a particular Machine. It also gives the details regarding Recipe Name. 68 . Recipe Number.

Stock Tank 4. Cycle Time 8. Main VAT Tank 2. Status Indicators 5. Levels Of the Tanks 6. Different Temperature Levels 9. Digital Panel Meters 7. Add Tank 3.Diagrammatic Representation of Dyeing Plant This Form displays the details of the entire working of Every Dyeing Machine Control including all the parameters such as: 1.18) Diagrammatic Representation of Dyeing Plant:- Form 17:. Machine Number 69 .

70 .18) Downloading Recipe from Dedicated Controller :- Form 18: Downloading Recipe from Dedicated Controller The End User can use this form to download the executed recipe from the Micro Controller.

20) Data History Communication :- Form 19:.Data History Communication This form displays and helps to directly interact with dedicated controller to upload the new recipe and to remove the particular recipe from the dedicated controller or clear the memory of the dedicated controller. 71 .

All modules combined in advance and the entire program is tested as whole. This is to be done by comparing the performance of the modules against the system specifications.Testing Procedure and Implementation Phases:Testing Procedure Software testing is a critical element in any software development and represents the ultimate review of the software design and coding. Integration Testing Integration testing is done to uncover errors associated with the interfacing. Testing provides the last and best way of finding errors in system. 72 . The Unit testing for the Dyeing Machine Control System for Dalal Engineering has been done by testing each of the modules such as to store the recipes. In this test the interface and the error handling conditions are tested thoroughly for that module. Unit Testing Unit testing check the smallest unit of the system.module. Testing begins at the modular level and works outwards the testing of the entire system. The testing is started at MIMIC control panel. It helps check and confirm that even the smallest unit of the system is working as expected. Master. Slaves to store data and finally give the result to the end user. The integration for the Dyeing Machine Control System has been using top down approach. This process helps to identify errors the thew module level. make daily history etc.

System Testing

System testing is done to test the entire system as a whole and to check the overall performance of the system.

After unit and integration testing is conducted by testing the entire Dyeing Machine Control System for Dalal Engineering as whole on a platform specified.

Implementation Phases

The system will be implemented in 3 phases i.e.

Phase I. Full details of the system given to all concerned authority. Phase II. Train all the Supervisors who are going to use the system. Phase III. The system will be executed simultaneously with the manual system, incase of any failure the routine work will not be hampered.

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Drawbacks and Limitations
Since it is an SSI unit, the promoters will be responsible for commercial and its technical growth.

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Proposed Enhancements

The system can be further enhanced by making the following enhancement:

1. The system does not include the databases regarding to the MIMIC control Panels. As such scope exists for further improvement by integrating the system with the above mentioned modules.

2. An additional forms and databases are added regarding to the

proposed development of the system. This is not the completed system; it is an in First Stage of the Development.

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Conclusion The developed system helps to deal with the Dyeing Machine Microcontroller which helps to replace the manual manpower by the totally Automated System Which helps to set different parameters which were set manually by the Machine Handler before would make lots of errors which would result some differentiation in the expected Color Combination required by the Users or Customers. It also helps to Machine Handlers as. It helps the organization to save its Manpower and even the important time to prepare the recipes once and store the recipes and make use of them whenever necessary. Easy To handle Time Saving Maintaining Different Temperatures. Handling Of 30 Machine at a Time 76 . Pressures. Managing Flow of Mixtures thought the Tanks.

B. 6.0 1st Edition BPB publication Author Title of Book Edition/ Year Name of the Publisher : : : : James Axelxon Serial port complete 3rd Edition Pen Ram International 77 .Bibliography Author Title of Book Edition/ Year Name of the Publisher : : : : Steven Hulzner V.0 Programming Black Book 30th Edition Dream Tech Author Title of Book Edition/ Year Name of the Publisher : : : : Ebangelos Patroness Mastering V. 6.B.

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