Automation In Textile Industry

DEFINITION OF AUTOMATION:-

Automation means not only reducing human labours and cost but also includes improvement in quality and profitability.

PURPOSE OF AUTOMATION:-

Automation is not the mere replacement of human labour, but rather the accompanishing of three things:-

1) Improvement of marketability of the product to ensure the selling of more units, and thus the generation of more income.

2) Improvement of efficiency of production, thus reducing unit costs while supplying the increased demand; and

3) Allowing optimal management control of both marketing and manufacturing thereby balancing income and expense to allow maximum profitability.

CHARACTERISTICS OF PROPER AUTOMATION:-

Proper automation ought to possess the following characteristics-

1) It should improve manufacturing efficiency, in terms of output and quality

2) It should improve product quality, in terms of customers quality requirements

3) It should provide a firm with the capability to practice either static flexibility-the ability to move easily within a product mix

4) It should contribute to the ability of management to exert control on the entire range of the firm’s activities.

BENEFITS OF AUTOMATION:-

1) Reduction in work-in-process time.

2) Reduction of work-in- process inventory.

3) Enhanced flexibility.

4) Improved scheduling and

5) Improved production control.

REGIONS OF AUTOMATION:-

Here, mainly we are concentrating on automation in-

I) spinning industry

II) Weaving industry

III) Wet processing industry.

IV) Knitting industry

V) Garment industry

I) SPINNING INDUSTRY:-

Spinning Mill Automation (SMA)

Toyoda has joined forces with a dedicated automatic transfer system manufacturer, so that customers have a range of flexible system options, allowing them to combine the FRD with an automatic transfer system for everything from simple transfer to fully-automated transfer.
Toyoda's spinning mill automation (SMA) is a labor-saving system which can be introduced to existing mills and adapted to meet a wide range of production needs.

SLIVER CAN TRANSPORT SYSTEM

Material handling system have been developed that can result in a highly automated, flexible mill for the complete processing short staple fiber from bale to cone using either ring or open spinning. An automatic sliver transport system using an automatically guided vehicle (AVG) can move sliver cans from drawing frames to roving frames or rotor spinning machines. This system eliminates tedious manual labor and automatically responds to the machines it serves. Other benefits include clearly arranged material flow, inventory, reduction and shortening of lot run times.

AGV AUTOMATIC GUIDED VEHICLE SYSTEMS

ROTOR LINK

SLIVER CAN TRANSPORT SYSTEM

Ü Advanced automation for sliver can transport.

Ü Capable of handling 15 sliver blends between drawing

and OE or MJS.

Ü Fast, trouble free, reliable performance.

Ü Inertial guidance system. No wires in floor or chemical paths.

Cotton Sorter

Detection and removal of contamination in raw cotton New machine: - more compact - better ejection system BARCO is proud to introduce the Cotton Sorter, a real time system for the detection and removal of contamination from raw cotton in the blow line. All unwanted material that differs from the cotton throughput is detected by ultra-fast CCD cameras and removed by means of high speed air guns. It is very easy to install the Cotton Sorter in an existing opening line. The system is installed in the pipeline that transports the cotton tufts from the bale opener. The cotton flow through the machine is straight. No need to add fan capacity to elevate the cotton and drop it through the inspection zone. The Cotton Sorter provides the means to safeguard a high and consistent quality level, regardless of operator practices. The early removal of contamination results in an improved and consistent quality level, less customer complaints and a higher efficiency on OE machines and winders due to a lower number of foreign fiber cuts by the yarn clearer.

QualiMaster

fabric inspection BARCO is proud to introduce its new "touch screen" based fabric inspection terminal, featuring a Windows-based Graphical User Interface for defect entry and real time display of the piece map. The BARCO QualiMaster production management system offers a powerful fabric inspection module that allows full quality analysis and fabric classification in first, second and third quality. Weaving plants equipped with the QualiMaster production monitoring system can integrate BARCO’s powerful "on-loom" inspection package, thus minimizing the risk for off-quality fabric in the weaving plant and reducing the workload in the grey fabric inspection department. For finished fabric inspection, special software for optimized mapping and cutting allows to maximize the first quality yield with a minimum of cut operations.

AUTOMATIC INSPECTION, WINDING, WRAPPING, CONVEYING AND PACKAGING SYSTEMS

r One source availability for the complete roll processing system

r Conveyor systems

r Lifting/lowering systems

r Roll system management systems

r Single and double doubling on rolls and/or flats

r Fabric folding on pallets

r Hot, cold and ultrasonic lengthwise cutting

r Automatic doubling and sewing machines

INSPECTION SYSTEMS

Automatic on-loom inspection BARCO’s automatic on-loom inspection system detects warp and filling defects by means of a moving camera system installed on the off-loom take up. In case of a warp defect or a concentration of filling defects, the system stops the loom, lights a warning lamp in the loom’s light tree and informs the defect nature and location on the loom’s micro-processor display. The system holds the loom in the stopped position till the weaver has made the "defect corrected" declaration. Cyclops avoids off quality fabric, in fact it stops your looms if the quality is not perfect. No need anymore for expensive and complicated automatic inspection systems or a manual inspection for greige fabrics. So, on top of a better fabric quality the logistics of your weaving mill gets simplified. Fabric can be sent directly to processing, no more inventory between weaving and inspection. Close collaboration with weaving machine builders allowed Barco to install the Cyclops in the loom, right under the sand roller. This shortens the distance between fell and defect detection considerably, allowing to stop the weaving machine much earlier in case of a running defect. Connected to BARCO’s WeaveMaster monitoring system, all defect information, pick stamped, is sent to a fabric quality data base. This allows to produce defect maps and various types of quality reports.

Cyclops on the batching motion at the loom Cyclops on the take up of a Dornier rapier loom producing industrial fabric. Cyclops installed in the Picanol Gamma full screen Cyclops installed in a Dornier Cyclops used for on loom inspection on glass fibre fabric

AUTOMATION IN DYEING

Loading and unloading of yarn package for dyeing is labor intensive, tedious, and strenuous. It is an excellent application for robotics. Most automated system use a robot to load and unload packages. The robots are designed specifically for package handling, and only the necessary degrees of freedom are included.

Loading and unloading of yarn package for dyeing is labor intensive, tedious, and strenuous. It is an excellent application for robotics. Most automated system use a robot to load and unload packages. The robots are designed specifically for package handling, and only the necessary degrees of freedom are included.

Dyehouse automation BEACON (Blackburn/UK) strengthens BarcoVision's position, in particular in Great Britain and the USA. It also gives BarcoVision/BARCO-Sedo access to the leather industry, in which BEACON has already built up a strong position. For several years BEACON Ltd has focused on developing automation systems for leather tanneries and leather colouring plants. With the BEACON and the BARCO-Sedo product ranges together, BarcoVision will be able to boost its market position by offering total solutions for textile dyehouses, including dye machine controllers and centralization systems.
	Fabric Printing Designing System

Sedomat 5000

Textile finishing automation
PLC integrated

The SEDOMAT 5000 is the cost effective solution for complete control and visualization of all types of textile dyeing and finishing machines. The active color display shows a windows user interface that requires little training. 

The SEDOMAT 5000’s powerful "open concept" with internal PLC, Profibus DP field bus and remote input/output allows connectivity with most available peripherals. This future oriented concept enables a modular approach to machine automation. 

The SEDOMAT 5000 can easily be integrated into a total CIM-concept.