dyeing machine control system
TRANSCRIPT
A PROJECT REPORT ON
DYEING MACHINE CONTROL SYSTEM FOR VIBRONICS PRIVATE LIMITED
SUBMITTED BYKAMBLE MANOJKUMAR SANTRAM MBA (2005-2007)
IN PARTIAL FULFILLMENT OF MASTERS DEGREE IN BUSINESS ADMINISTRATION
UNIVERSITY OF PUNE
THROUGH VISHWAKARMA INSTITUTE OF MANAGEMENT PUNE
Acknowledgement
Every project has a number of persons involved in it, some directly others indirectly. Everyone has contributed to its success; the critics who spur you into action with renewed enthusiasm and the supporters who steadfastly encourage you all through till the end. I would like to take this opportunity to
express my gratitude for all those who provided valuable criticism, appreciation and guidance to make this project a success. I thank Mr. Pramod Chavan my Training
Coordinator, Vibronics Pvt. Ltd. for the project, whose inspiration, whose sharing of anecdotes to exemplify the advice he would give, helped me see through this project swimmingly. I thank Dr. Vandana Gote my Project Guide for her guidance, motivation and attention. She was very much approachable with all my doubts! It was indeed a privilege to have done my project at Vibronics Private Limited. The learning experiences at Vibronics Private Limited are something that I would cherish for the rest of my life. Having worked in this corporation gives me the confidence and an outlook out of the box much needed before I take steps in the professional world.
Manojkumar Kamble Pune
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CONTENTSS. No. TOPIC PAGE NUMBER
1. 2. 3. 4.
EXECUTIVE SUMMARY OBJECTIVE AND SCOPE COMPANY PROFILE EXISTING SYSTEM & NEED OF THE SYSTEM OPERATING ENVIRONMENT PROPOSED SYSTEM REQUIREMENT DETERMINATION TECHNIQUES SOFTWARE ENGINEERING PARADIGM WORKING OF DYEING MACHINE CONTROLLER RUNTIME FORMS TESTING PROCEDURE & IMPLEMENTATION PHASES LIMITATIONS PROPOSED ENHANCEMENT CONCLUSION BIBLIOGRAPHY
1 2 3 20
5. 6.
21 22
9.
23
10.
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11. 12. 13. 14. 15. 16. 17.
33 45 68 70 71 72 73
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CERTIFICATE
This is certify that Mr. Kamble Manojkumar S. a student of M.B.A. (Systems) from Vishwakarma Institute of Management Pune has successfully completed his project work on Dyeing Machine Control System at
Vibronics Pvt. Ltd. Pune during the academic year 2005-2007 for the partial fulfillment of MBA from our guidance.
Dr. Sharad Joshi Director VIM
Dr. Vandana Gote Project Guide
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EXECUTIVE SUMMARYIntroduction:-
Vibronics, the Company serving the engineering industry for thirty-three years. With the commitment of excellence backed by intensive R
& D. With a branch network throughout India. Vibronics offers the finest in Ultrasonic Cleaning Systems and other products- backed by efficient person aliased after Sales & Services. Vibronics Private Limited is a Mumbai (India) based leading manufacturer and exporter of ultrasonic cleaning machine, ultrasonic cleaning solution, ultrasonic cleaning equipment, flaw detectors, ultrasonic processors, ultrasonic cleaning systems etc.
Vibronics Private Limited has been a forerunner in the field of ultrasonic devices. The company has been a catering to the engineering industry with its vast range of technically sound products. Our top quality and accurate devices are a result of the brainstorming efforts of technocrats. Apart from having a vast range of ultrasonic equipments, ultrasonic cleaners, we also manufacture a set of detergents that can pragmatically handle our ultrasound cleaners. Project Title:-
Dyeing Machine Control System.The Dyeing Machine Controller has a combination of three different Technologies viz. Embedded System, Software Visual Basic & Electronic Equipments, Microcontroller. Being a student of system apart from my software work I also got much more familiar & interesting part of Embedded System and various dedicated system which I was not familiar or worked on it before. 5
.
Objectives:To enhance the performance of the Dyeing machine System in the textile industries. Cost control. To increase the reliability of the Dyeing machine system. To reduce the manpower this is to handle the dyeing machines. Consistency. Integrity.
Scope:-
The textile industry nowadays don t have any automated system developed on which the Company can be reliable of what exactly the customer is in need of, to avoid this problem we developed this Automated System to overcome this problem. The Various Features this Automated Dyeing Machine Controller consists will help the Textiles Company to think on various color combination which can be applied as per the customer need within a span of period. The Automated Dyeing Machine Microcontroller also helps to control different temperature levels which are hard to handle by person manually and also the different water level along with the various Recipe s .
One of the important role this Dyeing Machine Microcontroller plays is that it help to save the manpower of Thirty Machine in a single phase of it s work. It also helps to make a impact of the company on Global World.
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Company Profile:Vibronics, the Company serving the engineering industry for thirtythree years. With the commitment of excellence backed by intensive R & D.
With a branch network throughout India. Vibronics offers the finest in Ultrasonic Cleaning Systems and other products- backed by efficient person aliased after Sales & Services. Vibronics Private Limited is a Mumbai (India) based leading manufacturer and exporter of ultrasonic cleaning machine, ultrasonic cleaning solution, ultrasonic cleaning equipment, flaw detectors, ultrasonic processors, ultrasonic cleaning systems etc.
Vibronics Private Limited has been a forerunner in the field of ultrasonic devices. The company has been a catering to the engineering industry with its vast range of technically sound products. Our top quality and accurate devices are a result of the brainstorming efforts of technocrats. Apart from having a vast range of ultrasonic equipments, ultrasonic cleaners, we also manufacture a set of detergents that can pragmatically handle our ultrasound cleaners. Vobronics Private Limited has two main achievements in the current days i.e. company has technically collaboration with Hansaonic Pte. Based South Korea, and along with the ultrasonic products the company has decided to provide the service in the industrial automation. The PC based industrial Automation System.
Some Myths and facts .
There are numerous misconceptions related with ultrasonic cleaning
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processes, they include: The louder the cleaner the better Poor insulation or a low frequency system maybe the main cause of loudness.
The quiter the cleaner the better Higher frequency operation and good insulation may lead to quitness.
Visual observation or ultrasonic power meter, the best option They are the perfect means of judging a cleaner
Factors in Cavitation The numerous factors that are responsible for cavitation are as follows: Frequency - higher the frequency the faster the cavitation and vice-versa.
Physical properties of cleaning agent - these include attributes like: Viscosity Vapor pressure Temperature Density
The ultrasonic cleaning process Ultrasonic cleaning mechanism is a an effect created by the action of sound waves at high frequency, introduced into liquid cleaning medium. The process consists of four major components like: Transducer Generator Tank Cleaning solution Aqueous Cleaning This cleaning uses water as its main solvent and has synthetic detergents and surfacants combined with special addictives such as builders, pH buffers, inhibitors, saponifiers etc.. It utilizes the synergetic effects and offers multiple degrees of freedom in concentration and blending. Its key stages include: -
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Washing Rinsing Drying Wastewater disposal
The merits and Demerits ADVANTAGES Aqueous cleaning system has several advantages over organic solvent cleaning. Safety Cleaning Inorganic or polar soils Oil and grease removal Multiple cleaning mechanism Ultrasonics applicability Chemical cost
DISADVANTAGES Depending upon the specific cleaning application, however, there are also some disadvantages.
Cleaning difficulty Rising Floor space Drying Material compatibility Water Energy consumption Wastewater disposal - in some instances , the use of aqueous cleaning may require wastewater treatment prior to discharge.
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Industries Served
Rayon Industries Poly Film Industries Polyester Industry Gear Industry Wire Industry Watch Industry Pump Industry Automobile Industry Compressor Industry Machine Tool Industry Electroplating Industry Brass Art Ware Industry Ball Pen Industry Semiconductor Industry Picture Tube Industry Electronic Component Industry PCB Manufacturing Industry Hospital & Pharmacy Industry List Of Competitors: AMICO INDUSTRIES PVT LTD ENRTECH PVT LTD RADIX PVT LTD
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BRANCHES AND OFFICES
Vibronics Pvt. Ltd. Mr. Akolawala Mustufa W-400, TTC Industrial Area, MIDC, Rabale Navi Mumbai, Mumbai - 400 701, Maharashtra, India Tel : +(91)-(22)-27690440/27690593/27690636 Fax : +(91)-(22)-27690440/27690593/27690636 Email : [email protected] | [email protected] For further information contact your Branch/Office.
DELHI OFFICE : 40, Yusuf Sarai, 1st floor, Green park, Delhi - 110016, Tel : (011) 6525149, 6966186, 6866730,. Fax : (011) 6866730, 6966186
SECUNDRABAD OFFICE : Srinivasa Enterprises, Tirumala complex, 126/A, S.D.road, Secundrabad - 500003. Tel : (040) 7819928, 7867652, 7849910, 7847546 Fax : (040) 7847546.
AHMEDABAD OFFICE : AARKEY Associates, Lalit complex, Near Jain Temple, Navrangpura, Ahamedabad- 380009. Tel : (079) 6562466, Fax : (079) 6562466
CHENNAI OFFICE : RESID. ENGR. -M/10/S-4, TNHB FlATS. THIRUVALLUVAR NAGAR, THIRUVANMIYUR, CHENNAI-600041. Tel : (044) 4404114, Fax : (044) 4915985
KOLKATTA OFFICE : M/S. Hindustan Trade Agency, 1, R.N Mukherjee Road, (Martin Burn House) 5th Floor, Room No. - 19, Kolkatta - 700 001
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Telefax : 2107091/ 92/ 6524
PUNE OFFICE : G-203, Vrindhavan Heights, Opp. Guru Ganesh Nagar, Paud Road, Pune - 411 029, Maharashtra. Tele : (020) 528 2708, Email : mailto:[email protected],[email protected],[email protected],mcpai [email protected]?subject=Vibronics Pvt. Ltd. Mail Through vibronicsindia.com
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PRODUCT RANGE:Ultrasonic Cleaning System :-
ULTRASONIC CLEANING
the process
Electrical Energy from a transistorized oscillator circuit is fed to the transducers. These piezo electric transducers convert electrical oscillations to corresponding mechanical vibrations and cause the tank bottom to vibrate, resulting in intense agitation of the liquid contained in the tank. This intense disturbance in the liquid contained in the tank will cause to form and collapse of millions of microscopic cavities or voids known as cavitations. When these cavities collapse or implode they release tremendous energy and produce an intense local scrubbing action on the objects immersed in the liquid, for cleaning.
Ultrasonic cleaning systems... features Complements industrial cleaning process Provides high intensity cleaning action with optimum efficiency Economical, safe and compact procedure Specially designed for rapid and thorough cleaning of small and large components and assemblies Results in efficient cleaning of metal, plastic, ceramic, alloys etc. Usable with high temperature detergents, for derusting, decarbonising, descaling etc. Greater efficiency with high intensity cleaning. Rigorous cleaning of intricate parts that are normally inaccessible
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Fig 1: Ultrasonic Cleaning System
MULTISTAGE CLEANING SYSTEMS:-
The Multistage Cleaning systems normally have 3 stages - precleaning, ultrasonic and vapor cleaning / dying. The system is ideal for degreasing, derusting, descaling, decarbonising and other cleaning requirements of automobile engineering, electrical and electronics and textile industries. Continuous filtration, recirculation, automatic distillation, water separation, and automatic / semi-automatic material transfer system are the features of the system. Fume extractions and chilling plant facilities are optional. The cleaning system is custom built on turnkey basis.
Technical Specification
Tank Material : Stainless steel/mild steel rubber. Lined fibre glass reinforced Tank Capacity : 3 ltr. onwards Cleaning technique : Ultrasonic and/or jet spray Frequency : 25 KHz to 43 KHz Ultrasonic power : 120 watt to 25 kw Mounting : Epoxy bonded/wielded/immersible module Transducers : Piezo electric-sandwich mode
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Jet Pressure : 30 to 600 PSI Liquid flow : 2 ltr. To 20 ltr. Per min.
Fig :- Multistage Cleaning System
SINGLE
OR
MULTISTAGE
VAPOUR
DEGREASERS
WITH
SOLVENT RECOVERY FACILITY Vapor degreasers are fully integrated efficient degreasing systems. They are rugged, built-in stainless steel with efficient condensation and water separation facility. All models of this series incorporate boiling sump for generation of vapours and removal of soil, grease, wax and other solvent soluble soils from intricated cavities. Vapor degreasers can be alternatively used as solvent recovery plant with correct selection of heat loads and valves.
Salient Features The prime features of the multistage vapor degreasers are as follows: Effective condensation and water separation Heat insulation
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Digital controllers Vigorous vapour generation chambers Low/high level central with alarm Dust and vermin proof control panel
Fig :- SINGLE OR MULTISTAGE VAPOUR DEGREASERS WITH SOLVENT RECOVERY FACILITY
Ultrasonic Flaw Detectors 1. Field operation specials Models available: FD 301 M, FD 301 MP, FD 401 MP An ideal instrument for filed operation, it provides precise quantitative evaluations with the simplest of controls that anyone can handle. Both models are powered by rechargeable batteries housed inside the main units. A plug in battery charger permits the battery to be charges without removal from the main unit.
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Technical specifications for FD 301 M, FD 301 MP, FD 401 MP Frequency range Vertical Linearity Gain Gain control 0.5 MHz to 12 MHz + 2% 140 dB 80 dB in Steps of 2 dB + 6 dB stepless Depth range Delay Ranges provided Upto 5 mtrs in steel 3 mtrs of steel 1,5,10,50,100 cms
with a multiplying factor of 5 Time base linearity PRF Better than 1% Variable from 1 KHz to 125 Hz interlinked with range Display Operating temperature 70 x 55 mm 40C to 60C
2. Vibronics rail tester Model: FD 301 R It is used for testing of rails during manufacture and after for fatigue cracks. The unit employs five double probes, two of 70 and 37 forward backward type and one special 70 double probe. Provision is made for a water tank to enable a constant water supply for probe coupling. The whole unit is made to RDSO'S specifications and has its approval.
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3. Vibronics plate tester The flaw detector is mounted on a trolley with universal movement. The trolley is housed with 4 MHz double crystal probe and built-in water tank to ensure continuous couplant for the probe. The equipment is totally battery operated. Additional angular probe and digital attachment are optional.
5. Vibronics accessories Carrying case Gives added protection to instruments at all times.
Calibration blocks The instruments' performance can be checked and adjusted regularly and easily, using standard calibration blocks.
Batteries Reliable long life cycle rechargeable batteries for use in all portable instruments. Available in 5 hrs or 8hrs chargeable time.
Probe cables Standard BNC to BNC available ex-stock for length from 2 meters onwards. Special cables like BNC lemo etc. supplied on request.
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Fig :- Ultrasonic Flaw Detectors
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Ultrasonic ProcessorsIt is a vivid and multi-dimensional instrument that covers a variety of samples such as aerated liquids, biological specimens, dyes etc. This equipment is basically used for research and small volume production. Some of its applications include: Cell disruption Enzyme extraction Deaeration
Advantage It has a great advantage over the traditional ones, such as: Pressure mixing Magnetic stirring Colloid mill
Cell disruption Ultrasonic processors cause ultrasonic "cavitation". During caviatation, shock waves at sound frequency cause great alterations of pressure those results in formation of large masses of vacuous bubbles. These bubbles grow until a critical stage is reached. Then they implode and disintegrate, giving rise to intense local shock waves, high instantaneous temperature and micro streaming of the liquid, round the point.
Product description It comprises of an electronic generator that generate 120 to 250 watts of average electrical energy. The transformer or velocity horn amplifies the small vibrations. It is attached to a pair of lead Zirconate titanate transducer elements. The 2 models available with us are: Model VPL-P1 of power 120 watts & dia " Model VPL-P2 of power 250 watts & dia 1"
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Ultrasonic Processor
medical cures
Our product can offer cure for the following medical problems(1) Blood sugar/Diabetes (2) Acidity/Gas (3) Cleaning of blood (4) Pimples, skin irritation, itching (5) Indigestion (6) Hair loss.
Fig:- Ultrasonic Processors
New Range, Cleaning Chemicals
New Range With the objective of diversifying it's field of production and providing effective cleaning chemicals and industrial detergent, Vibronics Private Limited has come out with a new range of detergents.
Cleaning Detergent After a lot of R&D and efforts, we have struck the right note the form of these cleaning detergent. Their salient features include easy availability, economy 21
and most importantly, efficiency.
An exhaustive list of the ingredients of these chemicals is given below. These materials determine the acidic, alkaline or neutral nature of these detergents.
Ingredients :
Degreasing Agents Vibrosol GDA Vibrosol GDC Vibrosol GDF Vibrosol GDH Vibrosol DCB Vibrosol DRH
Descaling Agents Vibrosol DRD
Descaling Agents Vibrosol DSA Vibrosol DSD
Decarbonising Agents Vibrosol DCB
Lancquer/Varnish/Paint remover Vibrosol DLP
Cleaning & Brightening chemical Vibrosol MBA Vibrosol BCA
Dewatering chemical Vibrosol RPD 22
Our technical team is always available for your assistance. The chemical wing is ready to solve your cleaning problems. Whatever the problem and whenever it arises, we are there for your service.
Fig :- cleaning chemicals
Fig:- industrial detergent
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Existing System and Need for the System
Existing SystemDyeing Machine Handling in Textile Industries:
In the existing system when a worker or end user work on a single machine & he handles a single machine manually it takes a lot of time to apply different color shading in the Dyeing machine. The worker who works on the machine has technically strong knowledge about handling a single machine at a time and he is not capable at the same time to apply the different colors to different fabrics at the same time as per the Customer requirements.
One important drawback of the existing system from the Organization point of view is that every machine requires a separate worker and special training to handle the same machine. The theme here is wastage of manpower per machine as well as the training for the each worker who handles the machine. In the existing system there are so many drawbacks which are non recoverable for any textile industry.
New SystemIn the new system we provide Dyeing Machines Control System to textile industries to automate their Dyeing machines to increase the performance and reduce the manpower as well as control the cost factor. In this System, one man can handle the 30 dyeing machines at a time and gives different color shades to the fabrics as per the Customer requirement. This system provide to store the different recipes on a micro- controller chip and reuse it when required, means to increase the reliability of the worker.
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Operating Environment
Hardware and Software
The proposed system has been developed using Visual Basic 6.0 as a front end and MS- Access, Embedded System, Micro Controller i.e. LPC 2141, & RS- 485 Protocol. It incorporates SQL & provides a graphical user interface (GUI).
Operating System
The proposed system can work on under Windows 9x, Windows NT 4.0, Windows 2000 and Windows XP as a operating System.
Hardware Configuration
The following is the minimum Hardware configuration required Processor RAM Hard Disk Micro- controller Protocol : Pentium 2.8 MHz. : 128 MB. : 20 GB. : LPC 2141. : RS- 485.
The following are the Recommended hardware configuration work without any problem in a long run.
Processor RAM Hard Disk Micro- controller Protocol
: Pentium III 2.8MHz. : 256 MB. : 20 GB. : LPC 2141. : RS- 485.
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Proposed SystemObjectives to be fulfilled
To enhance the performance of the Dyeing machine System in the textile industries. Cost control. To increase the reliability of the Dyeing machine system. To reduce the manpower this is to handle the dyeing machines. Consistency. Integrity.
User Requirement
To Maintain the Tank levels of Dyeing Plant in Textile Industry. To maintain different Temperature, Pressure of the Dyeing Machine. To maintain the different Water & Color Flow. To Reduce the Manpower to maintain the Cost Factor of the company. Consistency & Reliable System. A Facility provided for storing the color combinations by the use of Recipe Storage System within the Dyeing Machine to avoid repetition of work on the same color combination of the fabrics to be applied. Requirement of all the details every day regarding each Dyeing Machine and the Recipe it worked on.
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Requirement Determination Techniques and system analysis method employed.
What is Requirement Determination?
Requirement Determination involves studying the current business system to find out how it works and where improvements should be made. Systems studies result in evaluation of how current methods are working and whether adjustments are necessary or possible. These studies consider
both manual and computer methods as we shall see; they are not merely computer studies. A requirement is the feature that must be included in a new system. It may include a way of capturing or processing data, producing information, controlling a business activity, or supporting management. The determination of requirements thus entails studying the existing system and collecting details about it to fins out what this requirement are.
Activities in Requirement Determination It is helpful to view requirement determination through the three major activities of requirements requirement specification. anticipation, requirement investigation, and
Requirement Anticipation
Foreseeing systems characteristic based on previous experience. May cause the analyst to investigate areas and issues that could otherwise overlook. May also introduce focus.
Requirement Investigation:-
Study and documentation of current system, using fact finding techniques, data flow analysis, decision analysis.
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SOFTWARE ENGINEERING PARADIGM [DATA FLOW DIAGRAMS & FLOW CHARTS]
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Data Flow Diagram of Dyeing Machine Control System
End User
Machine Network (1-30)
Machine Selection
Machine Utilities
Machine Recipe
Machine Comm n
OEM Parameter
Data History
Create New Recipe
List Of Recipe
Machine Configuration Machine Parameter Machine Timers
Recipe s
Data History
OEM Properties Micro Controller
Dyeing Machine
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MANUAL
Select Tank
MVAT
ADD TANK
STOCK TANK
Select Process MVAT1 FILLING MVAT2 RINSING MVAT3 HT DRAIN MVAT4 OV. CIRC. MVAT5 LT DRAIN MVAT6 OPEN MVAT7 P.F.REVERSEMVAT8 PRESSURI.
Y A
Select Process ADD TANK1 MAIN VAT ADD TANK2 INJECTION ADD TANK3 DOSING ADD TANK4 TANK CLEAN ADD TANK5 MIX & HEAT ADD TANK6 FILL
Z A
Select Process STOCK TANK1 FILL STOCK TANK2 MIX HEAT STOCK TANK3 MAIN VAT STOCK TANK4 MAIN STOCK STOCK TANK5 TANK CLEAN STOCK TANK6 P.F.REVERSAL
Z1 A
A A BB A
M CA
S CA
N CA
CT A
C CA
CO A
CU A
D DA
P CA
V CA
EE A
Q CA
W CA
F A
CR A
CX A
G A
H
MVAT9 DEPRESSU RI. MVAT10 HEAT&RU N
I
J
MVAT11 SQUEEZE
K
J Fig :- Data Flow Diagram of working of the MIMIC Control Panel
MVAT12 SHOCK RINSE
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FLOW CHARTS OF DIFFERENT PROCESSES 1) MVAT FILLING 2) MVAT RINSING
A
B
HOT
WATER LEVEL
COLD
WITH
RINSING COOLIN G HOT
WITHOUT COOLING
ENTER LEVEL
ENTER TARG ET
RINSE TYPE HOT/CO
COLD
ENTER RINSE PRESS START P/B TIME. ENTER TARG ET
ENTER CIR. Y
.
PRESS
Y
3) MVAT HT DRAINC
4) MVAT OVERFLOW CIRCULATION
D EFFLUENT DRAIN DRAIN TYPE HT DRAIN
ENTER TIME
PRESS START P/B PRESS START P/B Y Y
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5) MVAT LT DRAIN
6) MVAT PREPARE TO OPEN
E F
ENTER LEVEL
PRESS START P/B
PRESS START P/B Y Y
7) MVAT PUMP FLOW REVERSAL
8) MVAT PRESSURISATION
G ENTER FWRD. TIME
H
ENTER PRESSURE LIMIT
ENTER REVERS E TIME PRESS START P/B
ENTER PUMP SPEED
ENTER PRESSUR CONTRL. ENTER FLOW CONTRL
Y
PRESS START P/B
Y
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9) MVAT DEPRESSURISATION
10) MVAT HEAT &RUN
J I ENTER TEMP ENTER RESSURE LIMIT ENTER GRADIE NT PRESS START P/B ENTER HOLD TIME
Y
PRESS
Y
11) MVAT SQUEEZE
12) MVAT SHOCK RINSE
L K
ENTER NO. OF CYCLES
ENTER TIME
PRESS START P/B
PRESS START P/B
Y
Y
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HOT
1) AD1 MAIN TO ADD TANK
2) AD INJECTION
M
N ENTER LEVEL PRESS START P/B PRESS START P/B
Z Z
3) AD DOSINGO
4) AD CLEAN
PROBE=1
ADD LEVEL PROBE HOT
PROBE=0
P
ENTER CURVE NO.
ENTER OPEN TIME
PRESS START P/B
ENTER QUANT-ITY
ENTER CLOSE TIME Z
ENTER TIME.
PRESS START P/B
Z
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5) AD MIX & HEAT
6) AD ADD FILL
Q R ENTER MIX VALUE ENTER LEVEL ENTER TIME
ENTER TEMP
PRESS START P/B
PRESS START
P/BZ
Z
1) ST FILL
2) ST MIX & HEAT
S
T
HOT
WATER LEVEL HOT/COLD
COLD
ENTER MIX VALUE
ENTER TIME
ENTER LEVEL
ENTER TEMP
PRESS START P/B
PRESS START P/B
Z1 Z1
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3) ST MAIN TO STOCK TANK
4) ST STOCK TO MAIN VAT
U
V
ENTER LEVEL
ENTER LEVEL
PRESS START P/B
PRESS START P/B
Z1
Z1
5) STOCK TANK CLEAN
6) ST PUMP FLOW REVERSALX
ENTER FWRD. TIME
wENTER REVERS E TIME PRESS START P/B ENTER FLOW ONTROL Z1
ENTER DIFF. PR. FWD.
ENTER FLOW CONTRO L
PRESS START P/B
Z1
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Working Of Dying Machine Controller
This is the diagrammatic representation of the working of the Dying machine Controller it is divided into three different parts
1. End User. 2. Micro Controller. 3. Dyeing Machine.
1) End User:This part includes all the input from the user manually regarding the instructions to the machine or the expected work from the machine. It also sends the data through this frame to Micro Controller the form of RS-485 protocol and the language used is ASCII Hex.
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2) Micro Controller:Micro Controller plays an intermediate role between the End user and the Dyeing Machine. It receives the frame from end user and read the particular machine address which is stored in frame and sends this frame to particular machine and it also receives the frame from machine and sends it to End User.
3) Dyeing Machine:It follows the instructions which it receives through the Micro Controller and responds to whatever the input given and generates the appropriate results and sends the acknowledgement to the end user.
Development of multidrop RS485 interface.
The multidrop RS485 protocol is to be designed and developed to establish communication between microcontroller cards and PC. The function of
microcontroller card is to acquire machine related parameters. There will be total 29 machines. Individual machine has microcontroller card connected to PC over RS485 bus. The data acquired by the microcontroller card is transferred to PC using RS485 protocol developed by Photon Techniques.
The nature of physical parameters and respective sensor output as well as data format requirements of acquired data provided by BTRA in the initial stages.
Physical Parameters: 1. Temperature 2. Pressure 3. Production Rate 4. Energy Consumed 5. Machine On/Off status
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Sensors to sense the physical parameters Physical Parameters Temperature Pressure Production Rate Energy Consumed Machine On/Off Status Sensor Output Type Analog 0 to 5 V Analog 0 to 5 V Digital 116 pulses / sec Digital 0.3 Hz Digital 100 Hz
Physical Parameter Temperature Pressure Production Rate Energy Consumed Machine On/Off Status
Digital Value 10 Bits 10 Bits 16 Bits 8 Bits 1 Bit
Bytes Required 2 Bytes 2 Bytes 2 Bytes 1 Byte 1 Byte
The real time demonstration of RS485 protocol requires real time acquisition of data, hence designing of test jig for simulation of physical parameters is essential.
Jig is designed by Photon Techniques as per the specification of physical parameters provided by BTRA.
Jig designed was confirmed to BTRA and with the consultation, necessary modifications were done.
Development of software to acquire data of physical parameters. 1. Routines are written to acquire the data as per the format In multidrop system, multiple devices are connected over 2 wires. Here 29 microcontroller cards and PC are sharing the same bus. To avoid corruption of data due to data collision and misinterpretation of data, ASCII Hex format and Frame structure are used for transmission of data over the bus.
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In multidrop system any device can communicate with any device. If two devices are transmitting data at same time then there will be collision of data. To avoid this, master/slave configuration is used. PC will act as master and all microcontroller cards will act as slave. There will be communication only between master and slave and not between two slave. To identify the slaves, we have given the addresses ranging from 1 to 29 to each slave and higher end address is given to masters Only master can generate request for transmission of data from slave devices. To avoid misinterpretation of data transmitted between master and slave device, ASCII Hex format and frame structure is used. Data format over RS485 bus ASCII Hex format is used for serial transmission of data over RS485 bus. By using this format each byte is represented by pair of ASCII codes that represents the bytes 2 hex characters. This format represents any value between 0 to 255 using only ASCII codes 30H to 39H (for 0 through 9) and 41H to 46H (for A through F)
Frame design to transmit address, data and commands over RS485 bus. The frame is designed to do discrimination of serial data as address, commands and actual data.
Start of Device frame ID
Source ID
Functio n Code
Data Count
Data
Check Sum
End of NULL frame \0
Fig: - Frame Structure of the RS-485 Protocol Whenever data is transmitted on serial cable, it will be transmitted in frame format only. The frame will contain Start of frame Device ID (Address of receiving device) Source ID (Address of Transmitting device) Function code Data count (Count of data bytes transmitted) Data Check Sum (Check sum of data bytes)
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End of frame NULL (Termination of frame)
Data transmitted in frame has given a meaning only inside the function. We have designed a function code to give proper meaning to data for e. g. Function Code 01 is used for identification of slave (microcontroller cards) Function Code 02 is used for RTC programming of slave (microcontroller cards) Function Code 03 is used for Transmission of acquired data from slave to master (microcontroller cards to PC).
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Scientific Diagram of Dyeing Plant (1)
Fig:-Scientific Diagram of Dyeing Plant (1)
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The Overview of the Dyeing machine Plant
Fig: - Dalal Dyeing Plant (Final Screen)
It visualizes the entire working of this plant including all the aspects right from Main VAT Tank, Add VAT, and Stock Tank.
MIMIC Control Panel Tester:MIMIC control panel is designed to show the current working status of the one particular machine. It is designed to check the tank levels, digital panel meter values, status indicators on the user screen, push button indicators, buzzer etc. MIMIC control panel is directly communicate with the machine through micro- controller LPC 2141 and receive the reports of the machine.
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Form: MIMIC Control Panel Tester (Before Working)
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Form: MIMIC Control Panel Tester (After Working)
The MIMIC control panel is divided into six frames i.e. Tank levels, DPM, Status Indicator, Push Button Indicators, Buzzer, Message Number.
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Tank Levels :-
Main Vat level: - To show the level of the mixture of color in Main Vat Tank. Add Vat Level: - To show the level of the mixture of color in the Add Vat Tank. Stock Tank Level: - To show the level of the mixture of color in the Stock Tank.
DPM (Digital Panel Meter):-
To show the current numerical values of the Main Vat, Add Vat and Stock Tanks. There are 7 DPM s on the MIMIC control Panel; Main Vat: - First 3 DPM shows the values of Temperature, Pressure and Hold timer of the Main vat Tank. Add Vat: - 4th DPM to show the Temperature of the Add Vat Tank. Stock Tank: - 5th DPM to show the temperature of stock tank. 6th & 7th DPM to Show the flow of water level and turbo meter.
Status Indicators:These LED s are placed on different pipes to indicate whether the flow of water is through the pipes then & then only these LED s will glow. The conditions may be Vice-Versa. It also plays important role to show the different status of water flow which helps in our entire project.
There are 48 LED s on the user screen, they are follows,
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1. Rising 2. Inside Out 3. Outside In 4. Pressure Control 5. VENT 6. Heating 7. Cooling 8. Turbo Pump 9. Injector Pump. 10. Air 11. Pressure 12. Throttle 13. Supply to Back Cooler 14. Back Cooler isolating 15. Add Tank Spray 16. Add Tank Back Transfer 17. Drain 18. Low Temperature 19. High Temperature. 20. Effluent 21 Pressure Extractions 22. Direct Stream. 23. ADD Tank Transfer 24. ADD Tank Drain. 25. ADD Tank Transfer (Pump) 26. Stock Tank Transfer 27. Stop Tank Drain. 28. Direct Fed Water (Hot) 29. Direct Fed Water (Cold) 30. Stock Tank Heating. 31. Stock Tank Stirrer. 32. Stock Tank Feed (Hot) 33. Stock Tank Feed (Cold) 34. Stock Tank Spray. 47
Push Button Indicators: -
The total numbers of push button indicators are 24 in number which indicates different tools which are used for manual working.
Buzzer: -
This Buzzer plays an important role which is used by the machine handler to indicate if any problem occurred.
Message Number: -
Whenever a problem is occurred Machine Sends a message to end user which signifies the machine in the network is having problem.
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RUNTIME FORMS
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1) The Welcome screen Of Dyeing machine Controller
Form1:- Welcome Screen
This form is the first form which the user will see on the screen. By clicking on the Enter Button he can proceed to Machine selection Form.
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2) Machine Selection Form.
Form2:- Machine Selection
This form provides the selection of machine on which the end user wants to perform the required instructions or Work. The end user can select any machine from the 32 machines by just selecting the particular no of the machine from the Drop down List. Then Click on the Proceed Command Button
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3) Utility Selection Form:-
Form3:- Utility Selection Form
Once you select the machine number then the utilities that are present on the screen of the particular machine. The total numbers of utilities are six which are:1. Machine Recipe:2. Machine Communication:3. DEM Parameter:4. Data History:5. Run Mode:6. Print:-
These are the various utilities which the End user can select and perform various action on that particular machine.
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Machine Recipe4) Recipe Information :-
Form4:- Recipe Information
This Form Shows the First Utility Recipe Information which displays the machine number which you have selected to perform actions, then it also necessary to enter Supervisor ID which signifies the Authenticated End user Name. The two Different Panels are 1. Create New Recipe:When a Authenticated Supervisor want to prepare a new recipe then he can enter mandatory fields i.e. Recipe Name, Description and Recipe Number. 2. List of Recipe:The List of Recipe s shows all the present list of Recipes of the particular machine of the Authenticated Supervisor ID.
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5) Actual Dyeing Recipe:-
Form5:- Dyeing Recipe
When a user is need of creating a new recipe this form plays a vital role and he can perform all the required actions. This Form is the main form which is divided into three different and important parts. They are as follows; 1. Tools 2. User Authentication 3. Recipe Tools : It is an the set of processes which operates the operations in the all three Tanks of Dyeing machine to perform the recipe. There are three subdivisions in this tools based on the different processes viz. 54
1. Main VAT 2. Add Tank 3. Stock Tank 4. Common Tank
1. Main VAT:There are twelve processes which is commonly used to perform the Dyeing Machine operations for Main VAT.
Processes Filling Heat and Run HT Drain LT Drain MV Circulation Prepare to Open Pressurization Pump Flow Reversal Rinsing Squeezing MV Steaming
Icon
Description To perform the filling operation to the Main Vat Tank. It perform the Heat and Run operation in the Main vat Tank. It performs the HT Darin operation in the Main Vat Tank. It performs the LT Darin operation in the Main Vat Tank. It performs the Main Vat Circulation operation.
It performs the Prepare To Open The Main vat Tank.
It performs the Pressurization operation In the Main Vat tank. It performs the Pump Flow Reversal operation in the Main Vat Tank. It perform the Rinsing of Water in The Main Vat Tank It performs the Squeezing Operation In the Main Vat Tank. It performs the Main Vat Steaming.
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2. Add Vat Tank
Processes Filling Heat and Run Dosing Injection MV To Add Tank Cleaning
Icon
Description To perform the filling operation to the Add Vat Tank. It performs the Heat and Run operation in the Add Tank. It performs the Dosing operation in the Add Tank. It performs the Injection operation in the Add Tank. It perform the operation of the transfer the Mixture from Add Vat to Main Vat Tank It performs the Cleaning operation in the Add Tank.
3. Stock Tank:Processes Filling Heat and Run MV To Stock Stock To MV Cleaning Icon Description To perform the filling operation to the Stock Tank. It performs the Heat and Run operation in the Stock Tank. It performs the transfer mixture MV to Stock operation. It performs the transfer mixture Stock to MV operation. It performs the Cleaning operation in the Stock Tank.
User Authentication :This Part consist of 1. Supervisor Id 2. Machine Number
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3. Recipe Name 4. Recipe Number.
Recipe Mixture :It is a consist of mixture of one recipe and steps to
perform that processes, it allows the end user to select the particular tool from the different processes and perform the required action on it as there are shown that the different Processes which starts with Main processes along with next Six Process which the end user can use to specify the action on that particular machine. And End user wants to save this recipe to perform same recipe on different machines, then he can save and use on different machines.
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6) Processing Properties:-
Form6 :- Processing Properties.
This form shows the properties of the particular process whose parameters the end user can manually change by selecting the drop down list and then clicking the OK command button to apply the properties to the process.
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7) Communication With Dyeing Machine:-
Form7:- Machine Communication
This Form Displays the Second Utility i.e. Machine Communication it consists of:-
1. Recipe 2. OEM Parameters 3. Data History
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OEM Parameters8) Selection Of OEM Parameters:-
Form8: Selection Of OEM Parameters
After Selecting the OEM parameters it will make the authentication request to the end user in response the user should specify the required details ..As
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9) User Authentication Form:-
Form9:- User Authentication Form
This form helps the End User to enter his security details. It is used to check the person is authorized person or not to see or to handle the Machine Parameters, Machine Configuration and Machine Timers because these fields are main to perform the machines.
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10) OEM Parameters:-
Form 10: -OEM Parameters
After entering the security check the user is redirected to thus form which consists of the actual OEM Parameters as
1. Machine Parameters 2. Machine Timers 3. Machine Configurations
All these can be manually changes or set by the end user as per his requirement.
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11) Machine Parameters Details :-
Form11:- Machine Parameters Details
After selecting the first OEM parameters i.e. Machine Parameters the table of machine details is displayed as shown above it consists the detail information regarding the performance of whole day which also help the end user to keep track of daily work done by it. The various fields in this table are 1. Machine Constant 2. Units 3. Min Value 4. Default value 5. Max Value It is also provided with a Save Command Button which helps to save the details of the particular or the selected machine every day.
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12) Machine Timers:-
Form 12:- Machine Timers
The second parameter of OEM is this Machine Timers It also displays the overall details of the Machine in tabular format. It helps to set the timer or the span of time in which we want to complete particular. In single line we can call it as setting a timer to complete particular work in a given span of period specified by the user.
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13) Machine Configuration:-
Form 13:- Machine Configuration
The Third Parameter of the OEM is Machine Configuration which allows the End User to perform the processes on the particular machine or not. Here there are two options specified click on the appropriate to perform or not to as per the Machine Requirement.
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14) Form Printing :-
Form14:- Form Printing
This Form Displays the two option of printing the recipe or the print history regarding the recipe. Along with the progress bar which signifies the process time completed.
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15) List Recipes:-
Form 15: List Recipes
This Form displays all the list of the Saved recipes on the particular Machines and Super Visor ID that are authenticated to that particular machine. And it also gives date & time of executed recipe on a particular Machine.
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17) Processes within the Recipe:-
Form 16: Processes within the Recipe
This form displays all the processes
within the executed recipe but
only after the selection of the particular recipe. It also gives the details of processing time required by each process on each machine.
It also gives the details regarding Recipe Name. Recipe Number, Recipe Starting Time, Recipe Ending time on a particular Machine.
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18) Diagrammatic Representation of Dyeing Plant:-
Form 17:- Diagrammatic Representation of Dyeing Plant
This Form displays the details of the entire working of Every Dyeing Machine Control including all the parameters such as:
1. Main VAT Tank 2. Add Tank 3. Stock Tank 4. Status Indicators 5. Levels Of the Tanks 6. Digital Panel Meters 7. Cycle Time 8. Different Temperature Levels 9. Machine Number
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18) Downloading Recipe from Dedicated Controller :-
Form 18: Downloading Recipe from Dedicated Controller
The End User can use this form to download the executed recipe from the Micro Controller.
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20) Data History Communication :-
Form 19:- Data History Communication
This form displays and helps to directly interact with dedicated controller to upload the new recipe and to remove the particular recipe from the dedicated controller or clear the memory of the dedicated controller.
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Testing Procedure and Implementation Phases:Testing Procedure Software testing is a critical element in any software development and represents the ultimate review of the software design and coding. Testing begins at the modular level and works outwards the testing of the entire system. Testing provides the last and best way of finding errors in system.
Unit Testing
Unit testing check the smallest unit of the system- module. It helps check and confirm that even the smallest unit of the system is working as expected. This is to be done by comparing the performance of the modules against the system specifications. This process helps to identify errors the thew module level. In this test the interface and the error handling conditions are tested thoroughly for that module.
The Unit testing for the Dyeing Machine Control System for Dalal Engineering has been done by testing each of the modules such as to store the recipes, make daily history etc.
Integration Testing
Integration testing is done to uncover errors associated with the interfacing. All modules combined in advance and the entire program is tested as whole.
The integration for the Dyeing Machine Control System has been using top down approach. The testing is started at MIMIC control panel, Master, Slaves to store data and finally give the result to the end user.
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System Testing
System testing is done to test the entire system as a whole and to check the overall performance of the system.
After unit and integration testing is conducted by testing the entire Dyeing Machine Control System for Dalal Engineering as whole on a platform specified.
Implementation Phases
The system will be implemented in 3 phases i.e.
Phase I. Full details of the system given to all concerned authority. Phase II. Train all the Supervisors who are going to use the system. Phase III. The system will be executed simultaneously with the manual system, incase of any failure the routine work will not be hampered.
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Drawbacks and LimitationsSince it is an SSI unit, the promoters will be responsible for commercial and its technical growth.
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Proposed Enhancements
The system can be further enhanced by making the following enhancement:
1. The system does not include the databases regarding to the MIMIC control Panels. As such scope exists for further improvement by integrating the system with the above mentioned modules.
2. An additional forms and databases are added regarding to the
proposed development of the system. This is not the completed system; it is an in First Stage of the Development.
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Conclusion
The developed system helps to deal with the Dyeing Machine Microcontroller which helps to replace the manual manpower by the totally Automated System Which helps to set different parameters which were set manually by the Machine Handler before would make lots of errors which would result some differentiation in the expected Color Combination required by the Users or Customers. It helps the organization to save its Manpower and even the important time to prepare the recipes once and store the recipes and make use of them whenever necessary.
It also helps to Machine Handlers as, Easy To handle Time Saving Maintaining Different Temperatures, Pressures. Managing Flow of Mixtures thought the Tanks. Handling Of 30 Machine at a Time
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Bibliography
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Steven Hulzner V.B. 6.0 Programming Black Book 30th Edition Dream Tech
Author Title of Book Edition/ Year Name of the Publisher
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Ebangelos Patroness Mastering V.B. 6.0 1st Edition BPB publication
Author Title of Book Edition/ Year Name of the Publisher
: : : :
James Axelxon Serial port complete 3rd Edition Pen Ram International
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