Virendra Oberoi-Automation in Ring Spinning Machines

AUTOMATION IN TEXTILE INDUSTRY

Virender Oberoi, GM Mktg, KTTM

An ISO 14001 Company

KIRLOSKAR TOYODA TEXTILE KIRLOSKAR TOYODA TEXTILE MACHINERY PVT LTD, BANGALOREMACHINERY PVT LTD, BANGALORE

Automation in Ring Spinning

Basic PolicyBasic Policy

““ Touch the Heart, People First Touch the Heart, People First ””

KTTM Company ProfileKTTM Company Profile

Operational PolicyOperational Policy

““ Speed up !Speed up !

Change & Challenge !Change & Challenge !

Zero defect ! Zero defect ! ””

KTTM Company ProfileKTTM Company Profile

1. Establishment 19951. Establishment 1995 14th August 1995

2. 2. Starting Operation 1997 6th June 1997

3. 3. Share Capital Ratio Toyota Industries Corporation : 95.1%

Kirloskar Group : 4.9%

4. 4. Range of Business Manufacture of Ring Spinning Frame

Export of Ring Frame Parts

Painting Job Work

Auto Parts Manufacturing

Sales & Service of Toyota Material Handling Equipments

KTTM’S BUSINESS ACTIVITIES

CAPITAL GOODSTEXTILE MACHINERY

AUTOMOBILE PARTS

JOB WORK MATERIAL HANDLING

SURFACE TREATMENT

FOR VOLVO, GE

TRANSMISSION COMPONENTS

FOR TOYOTA’S “IMV”

RING FRAME &COMPONENTS

SALE & SERVICE OF

TOYOTA MATERIAL HANDLING

EQUIPMENTS

CONSOLIDATED SALES TURNOVERR

s. in

Cro

res

54

105

178

233262

324

422

0

50

100

150

200

250

300

350

400

450

2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10

Projected

KTTM Ring Frame RXI240eKTTM Ring Frame RXI240eKTTM Ring Frame RXI240e

Innovations are carried out by Spinning

Machine Manufacturers across the globe.

This presentation is intended to focus and

sharing of information in perspective of

Toyota Industries corporation and KTTM.

Need for Automation• Man Power & Increasing Man Power Cost.

Spinning Mills are located in remote areas.

Difficult to get manpower.

Job other than actual production should be transferred to machine.

Example – Auto Doffer on Ring Frames.

• Changing job preferences.

Qualified Textile Technologists prefer to take white collar job like Marketing, Fashion Designing, Garmenting etc.

Not keen to work in production.

It should be possible to run production plant with few supervisory staff.

Example – Ring Data System, on line machine monitoring system, on line quality monitoring .

• Material Transportation

Material Transportation, within a spinning plant is a necessity.

It does not add any value.

Hence Link Winder System, Automatic Roving Transfer Systems.

• Increasing fashion consciousness resulting in smaller lot size.

This results in frequent changes in machine settings.

Therefore, Servo Drive system, which allow machine setting by touch of button.

• Ease of Machinery Maintenance.

Machines equipped with self guided informator, automatic lubrication, automatic waste removal.

Need for Automation

1. Ring Rail Movement – Conventional CAM Lift System

• Till recently most manufacturers use this mechanism.

• Cost effective & proven design.

• Involves too many components and mechanisms.

• Setting depends on human skills and require more time

• More space required

• More inventory needed of all parts

• Wear and tear of parts

• Fine adjustment difficult

Automation on Ring Frame

a) Servo Drive with Screw Lifting System

• Very reliable system.

• Controlled by servomotor and servo drive.

• Setting alteration by key pad data entry.

• No special skill needed for setting

• This system is still little expensive to implement

• Paticularly in Indian context.

• Assy time reduces enhancing manufacturing capacities.

As applied on Toyoda Ring Frame.

1. Ring Rail Movement – Alternative SystemAutomation on Ring Frame

• Setting done at the press of a button.

• No special skill needed for setting

• Combines the advantages of the servo drive system and at the same time is cost effective.

b) Electro Lift System – Innovative idea1. Ring Rail Movement – Alternative System


Vector drive -Motor

Controller

Input Data PLC Data Processor

Driving MotorLifting Gear Box

Perfect Cop Shape

• This system was possible to implement because of –

Thanks to companies like Siemens, Danfoss, ABB, Mitsubishi etc.. for bringing in advancement in motion & control electronics.

1. Ring Rail Movement – Alternative SystemAutomation on Ring Frame

2. Drive to Drafting Rollers – Conventional SystemAutomation on Ring Frame

• Conventional System, all gear drive

• Many gears to be changed for changing the count / twist. Time consuming process.

• Multiple types of yarns can be produced but needs additional mechanisms attached.

• Increased need for regular maintenance & repairs.

• Inventory of parts.

2. Drive to Drafting Rollers – Alternative SystemAutomation on Ring Frame

Electrodraft System

GE

MdMotor

Fr Motor

OEFr Roller(RH)

Fr Roller(LH)

Bk Roller(LH)MdMotor

Fr Control

Md Control

Md Roller(LH)

BkMotor

Bk Control

Bk Roller(RH)

Md Roller(RH)

2. Drive to Drafting Rollers – Alternative System


Electrodraft System

Back Roller Drive

DC 300V ~ 850V DC 24V

`

LIFTING GEAR BOX-1

Lifting Drive

~

=

330 ~ 480V AC, 3Ph, 50Hz +/-5%, THD (V) <5%

=~

M1 55KW

COMMUNICATION BUS

PLC (32 DI+16 RO / DO)

Display

==

Main Motor

98KW

55/75KW

During power failure synchronised stop for M1, M2, M4 ~ M10 required

SVC

=~

M2 1.5KW

2.2KW

SVC

GEAR BOX

Back Roller Drive

GEAR BOX-5

Mid. Roller Drive

=~

GEAR BOX-4

Mid. Roller Drive

GEAR BOX-3

Front Roller Drive

=~

GEAR BOX-2

Front Roller Drive

4KW 4KW

M5 1.5KW

M6 1.5KW

M7 1.5KW

M8 1.5KW

M8 1.5KW

SynchroniseSynchronise

SVC SVC

GEAR BOX-6

Back Roller Drive

M9 1.5KW

~ 4 K

SVC

=~

M3 1.5KW

2.2KW

SVC

=~

M4 7.5KW

7.5KW

SVC

Pneuma Motor

Position feedback

Synch

=~

M3 1.5KW

2.2KW

SVC

Doffing Motor

Pressure Transducer0~2500 Pa (-ve)

4~20mA

M10 1.5KW

GEAR BOX-7

KW

To achieve synchronized stopping of lifting and drafting Motors along with Main Motor by using Kinetic Energy available in the machine.

Main Inverter

Innovative proposed E-Drafting system

2. Drive to Drafting Rollers – Alternative System


Electrodraft System

• All rollers driven by individual motors, controlled by individual drives.

• Possible to alter draft and twist from the key pad. Fine tuning of twist & draft adjustments possible.

• Possible to manufacture fashion yarn like multi twist , multi count , slub yarn.

• Interfacing & drive communication through Profibus and other types of protocols makes controls simple and very accurate.

3. Pneumafil - Suction Pressure Monitoring System


Present System :

- Pneuma motor works at fixed rpm.

- Suction values achieved is fixed and has no relation to the material or count being processed.

Pressure Transducer

Feedback (0~4.5V DC)

3Φ, 415V AC

Suction Pressure Monitoring Tube

Motor

Inverter 7.5KW

Exhaust Air

Alternate System• Pneumafil motor is controlled

by inverter.

• Suction pressure can be set in inverter. This is constantly monitored by pressure transducer.

• Suction pressure can be set in relation to spindleage of the machine, count, and raw material being processed.

• Reduces power consumptionCase Study : Saving of about 1.2 units per hour

4. Automatic Doffer


• Automatic Doffer system is now gaining customer acceptance.

• Reduced manpower requirement.

• Increase machine productivity.

• Reduce need for supervision.

• Increase life of components and accessories like spindle & bobbins.

5. Link Coner System


• Automatic Cop Transfer from Ring Frame to Winder.

• Possible to implement spin identification system. ( on line quality monitoring & identifying the spindle producing inferior quality yarn).

• No mix up of different counts.

• No deterioration of yarn quality due to manual handling.

6. Automatic Roving Transfer


• Automatic Transfer of Roving Bobbins from Roving Frame to Ring Frame.

• No deterioration in Roving quality due to storage and handling.

• Better yarn quality.

7. Automatic Data Acquisition :


• All machines are connected to a Central Computer.

• Two way communication between the Computer and Machine can be established.

• Possible to change the speed parameters from the Computer.

• On line monitoring of the machine status.

• Data acquired can be converted to production report. No need to manually record the production information from the machine.

8. Automatic Breakage Control


• Machine can be interfaced with the Ring Data System.

• Spindle speed can be automatically increased / reduced depending on the yarn breakage level

• Brake is required on Ring Frame to prevent snarl formation while stopping the machine.

• Conventional system uses electro magnetic or mechanical brakes.

• Alternate system

• DC Injection brake from main inverter.

• Optimum braking time by varying the parameters.

• Elimination of all mechanical parts which require frequent resetting.

9. Machine Brake Automation on Ring Frame

Dream of all Machinery Manufacturers …….

AUTOMATIC YARN PIECING

AT

RING FRAMES


Thank you for your attention

Documents

Virendra Oberoi-Automation in Ring Spinning Machines