Automation in Textile Machinery Instrumentation and Control System Design Principles L. Senthilkumar Automation in Textile Machinery Automation in Textile Machinery Instrumentation and Control System Design Principles L. Senthilkumar CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2018 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U. Government works Printed on acid-free paper International Standard Book Number-13: 978-1-4987-8193-0 (Hardback) This book contains information obtained from authentic and highly regarded sources.
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Control Systems Engineering .5 Measurement of Voltage .6 Measurement of Small Voltages .7 Measurement of Current .8 Measurement of Small Currents .12 Avoid Signal or Ground Loops .14 Frequency Response and Filtering .17 The Non-Inverting Buffer .18 Operational Amplifier Properties .19 Operational Amplifier Circuits—Unity-Gain Non-Inverting Buffer .20 Non-Inverting Voltage Amplifier .21 Differential Voltage Amplifier .3 Cell Design for Electrochemistry .1 The Working Electrode.2 The Counter Electrode (or Secondary or Auxiliary Electrode) .3 The Reference Electrode .6 The Rotating Disk Electrode .4 Principles of Control Systems.1 Open-Loop Control System .2 Closed-Loop Control System.3 Automatic Control System .1 Functions of Automatic Control.2 Elements of Automatic Control .3 Feedback Control System Block Diagram.4 Stability of Automatic Control Systems .5 Two Position Control Systems .6 Proportional Control Systems .7 Proportional-Integral-Derivative Control Systems .1 Sensor and Transmitter .2 Primary Measuring Element Selection and Characteristics.2 Standard Signal Ranges .3 Electronic Transmitter Adjusted .4 Transmission System Dynamics .4 Smart Transmitter Microprocessor-Based Features .5 Characteristics of Instruments .2 Order of Control and Measurements Systems.1 Zero Order Control Systems .2 First Order Control Systems .3 Second Order Control Systems .3 Temperature Measurement Systems .1 Thermocouple Temperature Detectors .4 Instrumentation and Control: Pressure Detectors .1 Bellows-Type Detectors .2 Bourdon Tube-Type Detectors.3 Resistance-Type Transducers .4 Strain Gauge Pressure Transducer .5 Strain Gauge Used in a Bridge Circuit.6 Resistance-Type Transducers .7 Inductance-Type Transducers .9 Capacitive-Type Transducers .10 Pressure Detector Functions .2 Reflex Gauge Glass .5 Magnetic Bond Method .6 Conductivity Probe Method .7 Differential Pressure Level Detectors .8 Closed Tank, Dry Reference Leg .9 Closed Tank, Wet Reference Leg .2 Reference Leg Temperature Considerations .11 Level Detection Circuitry .9 Instrumentation and Control Module on Flow Detectors .1 Head Flow Meters .2 Hot-Wire Anemometer.4 Ultrasonic Flow Equipment .5 Steam Flow Detection .6 Simple Mass Flow Detection System .2 Use of Flow Indication .10 Instrumentation and Control Module on Position Indicators .12 Variable Output Devices .2 Linear Variable Differential Transformers .3 Position Indication Circuitry. Programmable Logic Control Systems .4 Ladder Logic Inputs .5 Ladder Logic Outputs .2 Programmable Logic Controller Hardware .1 Inputs and Outputs .3 Electrical Wiring Diagrams .1 Joint International Committee Wiring Symbols .2 Transistor–Transistor Logic .4 Solid-State Relays .5 Boolean Logic Design .3 Define Inputs and Outputs .3 Common Logic Forms .1 Complex Gate Forms .6 Programmable Logic Controller Operation .1 The Input and Output Scans .2 The Logic Scan .2 Programmable Logic Controller Status .4 Software-Based Programmable Logic Controllers .7 Latches, Timers, Counters, and More.4 Master Control Relays (MCRs) .8 Structured Logic Design .1 Process Sequence Bits .9 Flowchart-Based Design .10 Programmable Logic Controller Memory .4 Ladder Logic Functions .11 Analog Inputs and Outputs .1 Analog Inputs with a PLC .1 Pulse Width Modulation Outputs .1 Basic Brushed DC Motors .3 Brushless DC Motors .5 Wound Field Motors .1 Control of Logical Actuator Systems .2 Control of Continuous Actuator Systems.3 PID Control Systems .1 Water Tank Level Control. Instrumentation and Control Systems on Blowroom Sequence.1 Objective Measurement and Quality Control .3 Mixing Bale Opener.1 Automatic Bale Opener .2 The Multi-Function Separator .3 Mixer–Cleaner Combination with High Production Cleaner .1 Computer Controlled Cleaning Efficiency .4 Foreign Part Separator .6 Detection and Removal of Contamination .1 Premier Fiber Eye .1 Double Value with Premier Fiber Eye .2 Textile Cotton Eye—Contaminant Removal in Cotton .3 Detection and Removal of Contamination by Securomat .4 Cotton Contamination Cleaning Machine.7 Dust and Metal Extraction Machine .8 Automatic Waste Evacuation System (Intermittent) .9 Chute Feeding Systems. Instrumentation and Control System in Carding.1 Function of Carding .1 Different Types of Autolevelers.5 Precision Flat Setting .6 IGS Top Automatic Grinding System .8 Coiler Sliver Stop Motion.9 Thermistor Protection Unit .11 On Card Filter .12 Continuous Quality and Production Monitoring.
Instrumentation and Control Systems in Draw Frame and Speed Frame .1 Control Systems in Draw Frame .1 Principle of Measurement and Auto Levelling .3 Position and Range of Correction .4 Storage of the Measured Values .1 Principle of Measurement .1 Contamination Detection on Draw Frames and Lappers .2 Yarning Principle of Sliver Watch .3 Sliver Watch on Heather Yarns.4 Production and Quality Data .7 Automation Material Transport .2 CANlog—Handling System for Cans on Trolleys .3 CAN Link—Draw Frame Interlinking System .8 Sliver Expert System .1 Machine Setting Recommendations.2 Rapid Elimination of Faults .9 Integrated Draw Frame .2 Control Systems in Comber .1 Sliver Lap Machine .2 Ribbon Lap Machine .1 Ribbon Breakage Photo Cell .2 Comber Photo Control for Entry Lamp .3 Computer Aided Top Performance .4 Automatic Lap Transport.3 Speed Frame Controls .2 Multimotor Drive System .3 Automatic Winding Tension Compensating Device .2 Photo Master or Back Creel Stop Motion Unit .3 Roving Stop Motion. Instrumentation and Control Systems in Ring and Rotor Spinning .1 Control Systems in Ring Spinning .1 Existing Manual Operations.1 Need to Automate.2 The Possibilities for Automation .1 Drive of Highest Operational Reliability-PLCV .3 Individual Spindle Monitoring .1 Three-Level Operator Guiding System .5 Automations with Auto Doffer .1 Speed Control Through Inverter System .1 Production Data Collection .2 Production and Single Data Collection .1 Active Magnetic Levitation Principles .2 Flux Density and Force from Circuit Theory .3 Typical Magnetic System Geometry and Control .8 Monitoring and Control of Energy Consumption for Ring Frames in Textile Mills .1 Design of the System .2 The Input/Output Data of the System .3 The Features of the Instrument System.2 Controls in Rotor Spinning.1 Tasks of Rotor Spinning .1 Automations in Rotor Spinning .3 Automatic Piecing Devices .4 Event Identification System: Electronically Controlled Yarn Transfer.5 Automatic Suction Devices .1 New Suction System: Optimum Through-Flow .6 Foreign Fiber Detection System .1 Optical Measuring Principle Using Infrared Light .2 Individual Corolab ABS System .3 The Measuring Principle .7 Fault Recognition and Clearing .8 Moiré and Nep Detection.9 “Sliver-Stop” Function .1 Precise Monitoring of Yarn Counts.4 Variation-Length Curve .6 Online Hairiness Monitoring on OE Rotor Spinning Machines .7 Principles of Operation of the Hairiness Measuring Systems .8 UNIfeed®: The Universal Tube Supply System.9 Automatic Can Transport. Control Systems in Cone Winding Machine .2 Electronic Yarn Clearer .2 Photo-Cell Type.3 Electronic Anti-Patterning Device.1 Drum Lap Guard .4 Length and Diameter Measuring Device .5 Sensor-Monitored Winding Process .6 The Informator: Central Operating and Control Unit .7 Automatic Tension Controlling Device.1 Direct Drive System—Auto Torque Transmission .9 Variable Material Flow Systems .10 Winding Head Control .11 Full Cone Monitors .12 Automatic Package Doffer .13 Cleaning and Dust Removal Systems .15 Caddy Identification Systems .17 Package Quality Control. Instrumentation and Control Systems in the Warping and Sizing Machine .1 Control Systems in Warping .2 Automatic Feed Control System .3 Automatic Tension Controller .2 Reliable Fault Detection .4 Automatic Warp Divider .5 Automatic Warp Stop Motion .6 Precision Length Measuring Unit .7 Automatic Braking System .8 Beam Pressing Device .2 Measurement and Control Systems Used in Sizing.1 Pre-Wet Sizing .1 Compact Roller Arrangement .2 Eliminates Pre-Drying .3 Size Level Control .4 Automatic Tension Control on Single End Sizing .6 Size Application Measurement Control.7 Computer Slasher Control .8 Auto Moisture Controller .9 Evaluation of Sized Yarn .10 Automatic Marking System (Diagram).
Control Systems in Weaving .4 Automatic Pick Controller .5 Controls in Weft Insertion System.6 Let-Off Electronic Control Warp Beam .7 Electronic Take-Up Motion .1 Electronic Weft Detectors .8 Warp Stop Motion .2 The Warp Stop Motions for Large Width Weaving Machines .1 The Harness Warp Stop Motions .2 The Electro-Optical Warp Stop Motions .3 The Hayashi Optic-Electronic Warp Stop Motion .4 The Warp and Reed Protector Motions .5 The Contactless Stop Motions.9 Electronic Controls and Monitoring Devices on Shuttle Weaving Machines .1 Shuttle Flight Monitoring .1 The Principle of Operation of Electronic Shuttle Flight Monitoring .2 Electronic Monitoring Devices on Rapier Weaving Machines.3 Real Time Monitoring and Planning for the Weave Room .10 Electronic Yarn Tension Control .1 The Production Sensor .2 The Central Unit .3 The Three-Stop Connection.4 Connection Capacity of the Central Unit .1 Data Assurance with a Mains Breakdown .3 Distributed Control System.5 Handy Function Panel .5 Configuration of Loom Data System .6 Software for Loom Data .7 Data Processing in the Air-Jet Weaving Machine .1 Intelligent Pattern Data Programming.2 Network-Ready Touch-Screen Terminal .11 Sumo Drive System.1 Programmable Filling Tensioner .2 Automatic Pick Repair.3 Quick Style Change .12 Electronic Selvedge Motions .13 Weave Master Reporting Report and Formula Generator .2 Automatic Printing and Data Export .14 WeaveMaster Production Scheduling.1 Planning Warps and Pieces: The Graphical Plan Board .2 Printing of Warp Tickets and Piece Labels .3 Warp Out Prediction and Yarn Requirements Calculation .4 Looms with Ethernet Interface. Controls in Knitting.1 Designing and Patterning .2 Feeding Cone Indicator .3 Feeding Package Indicator .6 Oil Level Controller .4 Individual Needle Selection .5 Knitting Machine-Needle Detector.6 Knit Master System .1 Machines with Surface-Driven Packages .2 The Functions of the Knit Master System .3 All Solid-State Doff Counter for Knitting.7 Simodrive Sensor Measuring Systems .8 Monitoring Yarn Input Tension for Quality Control in Circular Knitting.2 Representation of the Waveform by a Measured Value .3 Defect Identification by Stitch Formation Differences .9 Warp Knitting Machine Control. Controls in Testing Instruments .2 Principle of Fiber Length Measurement .3 Fiber Diameter Analyzer .5 Fineness and Maturity Testing .1 Fiber Contamination Technology .6 High Volume Instrument .7 Advanced Fiber Information System .9 Electronic Twist Tester .10 Yarn Evenness Measuring Instruments .1 Choice of Measuring Indicator .2 Normal and Inert Testing .3 The Imperfections Indicator.3 Infrared Sensing Method .4 Variation in Thickness under Compression Method.11 Electronic Inspection Board .1 Electronic Inspection Board Process for Yarn Appearance Grade Evaluation .12 Hairiness Measurement—Photoelectric Method .1 Photoelectric Counting Method.13 Tensile Strength Testing of Textiles .1 Breaking Force Measurement.2 The Instron Tensile Testing Instrument .3 The Load Weighing System .14 Optical Trash Analysis Device. Automation and Control in Chemical Processing .1 Control Systems in Dyeing Process .1 Novel Control Concepts .2 Novel Control Schemes .3 Fuzzy Logic Control .4 Auto Jigger Controller System .5 Automatic Dispensing System .6 Online pH Measurement and Control.4 On–Off Control—Two Step .