Automation and Process Control in Textile Industry

At present, automation is one major key to quality improvement and cost competitiveness most textile sectors of individual machines and their processes. Now, every manufacturer wants to make completely automatic machinery that takes in raw material on its one end and delivers finished product from the other end.

The main objectives of Computer Integrated Manufacturing (CIM) are first to provide accessible information for every sector of a plant for the efficient operation of industries. CIM controls fiber preparation, opening, blending, carding and auto leveling in drawing. On-line quality control in carding and drawing can perform spectral analysis and determine the cause of problems based on the frequency analysis of the defects. Individual spindle drives in ring spinning, automatic end piecing, automatic doffing and automated inter process transportation system is performed by robotic mechanisms.
automation in textile industry
Weaving and knitting machine builders have been leading the way in utilizing computer technology in textile manufacturing for many years with their use of CAD, bidirectional communication and artificial intelligence. With the availability of electronic dobby and jacquard heads, automatic pick finding, and needle selection etc. These machines are the most easily integrated into computer networks of any production machines. CAD system can be used to develop the fabric to be produced and the design can then be transmitted over the network to the production machines to produce the desired fabric. Weaving also is the area where artificial intelligence is progressing the fastest with development such as expert system to assist in troubleshooting looms.

The application in sizing machines has increased to a greater extent such as multi-point thermo sensors for energy saving, automatic control of squeezing pressure, size pick-up detectors, multi-functional counters etc. Sizing machine control systems provide a tool for management to ensure that all warps are sized identically under standard operating conditions. These monitoring and control capabilities can be included in a computer network of a weaving mill.

The automation started with the introduction of system that controlled a set temperature by switching heaters on or off. A short time later these were replaced by systems that controlled the dyeing cycle according to a time/temperature sequence. The processes of dye and auxiliary chemical addition as well as loading and unloading of textile materials were also automated to result in automated dye house management. A monitor displays scheduling for any machine and allows the operator to arrange the next lot. Batch weighing updates inventory each minute and give inventory of each dye by bulk and container. Any errors later in the process can be traced to a particular container if it should become necessary.

Now, the jiggers have been fully computerized with total control over process. In the pad batch dyeing system, the most outstanding development is special dye dispensing system, on-line color monitoring and dye pickup control. Essentially Neutral Network and Fuzzy Logic are frequently being used. In the plant automated system directs the entire manufacturing process from dyeing to loading and unloading yarns. It knows what color and how much dye to add, when to fix it and when and where to route the yarn for the next step in the dye process. The system creates a highly effective and extremely efficient facility.

Recent advances in imaging technology have resulted in inexpensive, high quality image acquisition and advances in computer technology allow image processing to be performed quickly and cheaply. This has given rise not only to a number of developments for laboratory quality testing equipments for fibers, yarns and fabrics but also to developments of on-line equipments for continuous monitoring of quality in textiles such as Fiber Contamination Eliminator, Intelligent Yarn Grader and Automatic Fabric Inspection.
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