National Institute Of Fashion Technology

Department of Fashion Technology

Subject Name
Internet of Things

Assignment 1

Submitted to
Prof. S. Prabhakar

Submitted by
Alwin Basil Baby
Bipasha Baishya
Moneesh S
Vijaya Tharsne KS

Date
14/10/2022
Topic Chosen:

Thread tensioner

Aim:

To constantly monitor and control the thread tension while sewing happens. For
the threads like PA (Polyamide), PE (Polyethylene), PES (Polyester ), PP
(Polypropylene), Spandex etc

Objective:

1. To understand the movement of thread during the sewing operations and

the
2. The variations in thread tension that happens in the thread during
different operations.
3. What will be the issues that an operator faces due to the variation of
thread tension?
4. What is the exact tension value to maintain the stitch to be perfect to
prevent different issues?
5. How can the issue be resolved by introducing a device that makes the job
easier?

Issues:

● Needle thread tension is too loose

○ The needle thread needs to be tightened if the stitching thread
shows loops on the underside. On the other hand if the needle
thread is too tight, it will pull up the bobbin thread and also show it
on the topside. If this is the case, then loosen the needle thread
tension, but avoid adjusting both needle and bobbin tension.
● Bobbin thread tension is too tight
○ When loops form on the topside of the seam the bobbin thread
needs loosening.

● Seam puckering
○ If seams on lighter-weight fabrics are prone to pucker, loosen the
thread tension a little and adjust to a larger stitch length.

● Fabric stretching
○ This can happen when sewing fabrics cut on the bias or with some
stretch. Make sure you only lead the fabric through the sewing
process and gently push the fabric towards the foot; avoid
excessive pulling and pushing. It might also occur if the pressure
on the foot is too tight, in which case loosen the foot pressure.

● Skipping stitches
○ Many factors can lead to skipped stitches. Check if the needle has
been inserted in the right direction, is the right size and type, that
the point is not dull or bent and the machine is threaded correctly.

● Random loops
○ If the machine is not threaded correctly, or the thread has not been
placed properly inside the tension disks, a series of loops can
appear. A stitch regulator on an industrial flatbed sewing machine.
On this machine the stitch length can vary from 0–4mm.
○ This indicates that the tension is too loose on both the bobbin and
needle thread, the machine has not been threaded correctly, or the
thread has not been placed properly between the tension
mechanism.
Microprocessor: Adruino

Sensor: Yarn tension sensor

The yarn tension sensor's measurement methodology is based on the time-tested
Hall technology. Here, a signal proportional to the tension of the yarn is
translated into voltage by measuring the strength of the magnetic field. This
measuring principle's dependability has been demonstrated over a long period of
time by measuring precision. The sensor's compact and sturdy structural design
has also been tested in practice.
The yarn tension sensor is the ideal tool for yarn quality management. Highly
reliable tension monitoring allows exact supervision at texturing and other
industrial machines. Producers benefit from waste reduction and year-round
precision and quality reports in filament yarn productions.

The sensor is available in 3 main tension ranges:

• Low tension range: PA applications (0-60 cN)
• Standard range: PET applications (0-120 cN)
• High tension range: heavy counts and bulked continuous filament (BCF)
applications (0-240 cN).
​Yarn tension is the most important quality driver in texturing.

Advantage of using Yarn Tension Sensor

● Highest requirements for economic and secure processes

● Innovative Hall digital sensor technology
● Electronics protected from environment
● Designed for highest reliability
● Optimal long-term drift, temperature drift and accuracy
● Tension overload protection to prevent damage to the sensor
● Protection against electrostatic discharge and machine vibrations
● Resistance to common spin finishes
● Simple installation and implementation into thread path
● Application in texturing and other industrial machines for tension
surveillance

This yarn tension sensor is for measuring threads, fibres and thin wires with a
diameter up to approx. 2 mm
Actuator: LCD display

Panel mount digital display (1/8 Din Cutout), output signal, analog output and
user-set MIN and MAX alarm limits. All tension sensors series TS and LTS
with analog output signal 0 - 1 V can be connected.Three different calibrations
can be saved at this display unit.Available with digital output for data
processing with PC.

Circuit diagram:
Block diagram: