virendra oberoi-automation in ring spinning machines
TRANSCRIPT
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AUTOMATION IN TEXTILE INDUSTRY
Virender Oberoi, GM Mktg, KTTM
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An ISO 14001 Company
KIRLOSKAR TOYODA TEXTILE KIRLOSKAR TOYODA TEXTILE MACHINERY PVT LTD, BANGALOREMACHINERY PVT LTD, BANGALORE
Automation in Ring Spinning
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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 ! ””
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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
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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
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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
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KTTM Ring Frame RXI240eKTTM Ring Frame RXI240eKTTM Ring Frame RXI240e
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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.
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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 .
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• 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
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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
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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
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• 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
Automation on Ring Frame
Vector drive -Motor
Controller
Input Data PLC Data Processor
Driving MotorLifting Gear Box
Perfect Cop Shape
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• 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
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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.
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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)
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2. Drive to Drafting Rollers – Alternative System
Automation on Ring Frame
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
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2. Drive to Drafting Rollers – Alternative System
Automation on Ring Frame
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.
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3. Pneumafil - Suction Pressure Monitoring System
Automation on Ring Frame
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
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4. Automatic Doffer
Automation on Ring Frame
• 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.
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5. Link Coner System
Automation on Ring Frame
• 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.
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6. Automatic Roving Transfer
Automation on Ring Frame
• Automatic Transfer of Roving Bobbins from Roving Frame to Ring Frame.
• No deterioration in Roving quality due to storage and handling.
• Better yarn quality.
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7. Automatic Data Acquisition :
Automation on Ring Frame
• 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.
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8. Automatic Breakage Control
Automation on Ring Frame
• Machine can be interfaced with the Ring Data System.
• Spindle speed can be automatically increased / reduced depending on the yarn breakage level
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• 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
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Dream of all Machinery Manufacturers …….
AUTOMATIC YARN PIECING
AT
RING FRAMES
Automation on Ring Frame
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Thank you for your attention