Smart Textile Spinning Monitoring System IoT

Project Title

Smart Textile Spinning Monitoring System IoT

Project Area of Specialization Internet of ThingsProject Summary

Textile industry in Pakistan is the country’s largest manufacturing industry where it contributes 8.5% to the GDP of Pakistan. Pakistan is the 8th largest exporter of textile commodities in Asia. In addition, the sector employs about 45% of the total labor force in the country (and 38% of the manufacturing workers). Pakistan is the 4th largest producer of cotton with the third largest spinning capacity in Asia after China and India and contributes 5% to the global spinning capacity. At present, there are 1,221 ginning units, 442 spinning units, 124 large spinning units and 425 small units which produce textile.

                   A textile is a flexible material consisting of a network of nature Figure I or artificial fibers called yarn. Yarn is a long continuous length of interlocked fibers that is produced by spinning raw fibers of wool, cotton or other materials to produce long strands and thus the very first and foremost step in the whole textile industry is the manufacturing of yarn through Ring Spinning or simply Spinning mechanism.

                   Ring spinning process is a twisting technique where the fiber is drawn out, twisted, and wound onto a bobbin.  A roving is fed to the drafting system, the drafted roving is supplied through the yarn guide, called a lappet, to the ring-traveler system to impart twist to the yarn, which is wound up on the cop finally. The traveler itself rotates on the ring and is dragged with the spindle by means of the yarn that is attached to it. Each cycle of rotation of the traveler along the ring inserts one turn of twist to the yarn. The differential speed between the spindle and the traveler enables the twisting of yarn onto the bobbin.

      Figure I 

 However, the process is quite complicated and error prone due to its very nature.  End breaking defect rate is one of most crucial factors in determining profit and cost margins in yarn manufacturing. Furthermore, companies strive regularly to minimize the defect rate to scale up their business. Tapping early into the statistics of the defects of the involved processes can expand the production volume while minimizing the cost and effectively the loss.  In this project, we proposed a solution which is capable of offering unprecedented insights into spinning mills operations in terms of data collection and processing. The project incorporates various crucial elements such as competently built sensors, monitoring software that connects with an enterprise-grade application server, and user-friendly interface.

Project Objectives

  Our Objective is to provide a solution that is capable of offering unprecedented insights into spinning mills operations in terms of data collection and processing.Our solution will consolidate various key elements such that competently build sensors and microcontrollers, monitoring software that connect with an enterprise-grade application server and web-based interference. 

                              Firstly, the array of sensors at each spindle records spindles rotation and end-breaking data in realtime. This set of sensors includes various metrics such as temperature readings, relative humidity, speed differentials, downtime, and the position of the spindle at every moment. The data is continually reported to an in-house data collection and logging system (HMI) that will help track down any faults and evaluate the production efficiency of the system as well. Consequently, the server's functionality will be driven by a custom monitoring application which will fundamentally monitor all machines, configure sensors based on various thresholds, and conduct analysis on data to generate reports with rich attributes. Furthermore, all of this recorded data will be easy to access through a mobile-based interface at any time of the day in realtime.

Project Implementation Method

     The proposed solutions will incorporate three different types of designing and implementation techniques.

• Designing the hardware architecture of  arrays of sensors integrated with microcontrollers and power build-up circuits.

• Designing and managing data that comes from a wide variety of sensors transmitted it via serial communication to microcontrollers  governed by embedded system programming.

• Designing and implementing enterprise-grade application and server side configuration  that stored data in an in-house server that accumulates and processes on that data to generate compelling and rich reports at HMI.

 

Design Architecture of System: 

                                                                           Design of system architecture is mainly divided into two major parts .

 

1. Software Design Architecture:

                                                                  

• Embedded Programming

• Synchronize Microcontrollers

• Database Design

• The database will have the capability to store the time series parametric values involved in the overall operations through serial communication between firmware and servers. Different filters can be applied to view a precise data report with necessary details depending on the selection of filtration parameters. With reference to the whole inducting setup, managers can have data insights for each of the following critical factors .

• Breaks
• Highest end breaks machines
• Highest productivity per spindle machines
• Highest startup breaks machines
• Lowest AEF machines
• Production
• Alarm Analysis Trend
• Article Production
• Efficiency trend
• Machine efficiency
• Machine yarn breaks
• Production share per article
• Production trend
• Stops trend
• Yarn breaks trend
• Highest Chain Break Spindles
• Highest End Break Spindles
• Highest Idle Spindles

• 

• Mathematical Calculations

• Server-side configuration

• User Interference 

1. Hardware Design Architecture:

• Microcontrollers

• Sensors

• Circuit Components

• Power build-up Circuits

• Networking

Implementation Path:

• Hardware Path Implementation

• Microcontrollers Implementation

• Sensors Implementation

• Microcontrollers & sensors integration 

• Software Path Implementation

• Microcontroller programming

• Sensors data calculations

• Server side & application user programming

Benefits of the Project

Avoiding the wastage of yarn caused due to end breakage by using specific alarms and LEDs,the loss can be minimized. Identifying the faults and fixing them right away brings cost efficiency consequently. In minimum time we can find the affected spindle by using LEDs on each spindle,thus it saves time and cost. In addition, management has an insight into the performance delivered by their employed personnel. 

The proposed solution aims towards minimizing the frequency of end-breaks and providing a comprehensive view of the performance data – in real time. This data is made accessible remotely to the executives through a mobile application to gain real-time information on the production performance, HR efficiency and machine failures or stoppage.

This system monitors the productivity of all the spindles such that it can offer real time access to:

• Ring spinning performance data (e.g. Bobbin build-up report)

• Winding data

• Fault prevention information

Furthermore, losses can be reduced by smart monitoring and timely cleaning of machines facilitated by our reporting system. Damaged/overheated equipment can also be prevented by using appropriate sensors causing a boost in productivity. 

Technical Details of Final Deliverable

Our proposed solution is capable of offering unprecedented insights into spinning mills operations in terms of data collection and processing. The project incorporates various crucial elements such as competently built sensors, monitoring software that connects with an enterprise-grade application server, and mobile-based interface. 

The system has four major components that drive its operations.

1. Sensors.

2. Data Management & Alerts.

3. HMI Application.

4. Mobile Application.

2. Data Management and Alerts

The data from a wide variety of sensors is transmitted through controllers to HMI, which handles all logging requests. Sensors are connected through serial wires to the controller, which is an IP based device that connects to HMI through a LAN network. This data is stored in an in-house server that accumulates and processes on that data to generate compelling and rich reports at HMI.

2.1. Real time alerts and indicators in LEDs and System

-  The status of the spindles is continuously monitored, and abnormal status (broken / low twist /disabled spindles) are signalized by bright red  L.E.D. situated in the corresponding spindle position.

-  A bright tower lamp with 3 different colour alarms, installed in each corner of the machine, alarms the operator showing the side of the machine that needs urgent piecening. This allows the operator to completely change the patrolling path, saving lost time and increasing operator’s performances. Key advantages are as follows:

      -   Easy to pinpoint spindles producing low twist yarn

      -   Detection of disabled spindles

      -   Monitoring of end-breakings.

    

2.2 Machine Parts Condition

-   Machine maintenance history and monitoring of ageing of machine parts.

-   Age related wear of critical machine parts likely to cause end-breaks and quality defects.

-  Live view of the machine state on the portal  to take appropriate actions.

3. UI Application

Some intuitive reports related to monitoring of production and failure will be available in the mobile application. Moreover, it will provide a summary of the necessary operations as well as an overview of the performance of the machines. Performance of HR will also be analyzed through this application based on the efficiency of the fixes required to keep the system running. 

Design Architecture

Final Deliverable of the Project HW/SW integrated systemCore Industry ManufacturingOther Industries IT , Manufacturing Core Technology Internet of Things (IoT)Other Technologies Internet of Things (IoT), Cloud InfrastructureSustainable Development Goals Industry, Innovation and Infrastructure, Responsible Consumption and ProductionRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	77200
Raspberry Pi 4 Module B	Equipment	2	18000	36000
STM	Equipment	4	1200	4800
Arduino	Equipment	6	800	4800
IR Sensor	Equipment	18	400	7200
Proximity Sensor	Equipment	4	800	3200
Temperature and Humidity Sensor	Equipment	3	1000	3000
Energy Sensor	Equipment	3	1000	3000
Alarms and Buzzers	Equipment	4	800	3200
ICs and Circuit components	Equipment	50	80	4000
Designing and Accessories	Miscellaneous	8000	1	8000