04-09-2014, 02:33 PM
Vardhman Group is a leading textile group in India having a turnover of $1009 mn. Spanning over 25 manufacturing facilities in five states across India, the Group business portfolio includes Yarn, Greige and Processed Fabric, Sewing Thread, Acrylic Fibre and Alloy Steel. Vardhman Group manufacturing facilities include over 10,48,160 spindles, 450 metric Tons per day yarn and fibre dyeing, 1300 shuttleless looms, 115 mn meters per annum processed fabric, 34 tons per day sewing thread, 20000 metric tons per annum acrylic fibre and 1,20,000 tons per annum special and alloy steel. Vardhman has evolved through history from a small beginning in 1965 into a modern textile major under the dynamic leadership of its chairman, S.P.Oswal. His vision and insight has given Vardhman an enviable position in the textile industry. Under his leadership, Vardhman is efficiently using resources to innovate, diversify, integrate and build its diverse operations into a dynamic modern enterprise. The industrial city of Ludhiana, located in the fertile Malwa region of Central Punjab is otherwise known as t
Vardhman Group is a leading textile group in India having a turnover of $1009 mn. Spanning over 25 manufacturing facilities in five states across India, the Group business portfolio includes Yarn, Greige and Processed Fabric, Sewing Thread, Acrylic Fibre and Alloy Steel. Vardhman Group manufacturing facilities include over 10,48,160 spindles, 450 metric Tons per day yarn and fibre dyeing, 1300 shuttleless looms, 115 mn meters per annum processed fabric, 34 tons per day sewing thread, 20000 metric tons per annum acrylic fibre and 1,20,000 tons per annum special and alloy steel. Vardhman has evolved through history from a small beginning in 1965 into a modern textile major under the dynamic leadership of its chairman, S.P.Oswal. His vision and insight has given Vardhman an enviable position in the textile industry. Under his leadership, Vardhman is efficiently using resources to innovate, diversify, integrate and build its diverse operations into a dynamic modern enterprise. The industrial city of Ludhiana, located in the fertile Malwa region of Central Punjab is otherwise known as the "Manchester of India". Within the precincts of this city is located the Corporate headquarters of the Vardhman Group, a household name in Northern India. The Vardhman Group, born in 1965, under the entrepreneurship of Late Lala Rattan Chand Oswal has today blossomed into one of the largest Textile Business houses in India. At its inception, Vardhman had an installed capacity of 14,000 spindles, today; its capacity has increased multifold to over 10 lacs spindles. In 1982 the Group entered the sewing thread market in the country which was a forward integration of the business. Today Vardhman Threads is the second largest producer of sewing thread in India. In 1990, it undertook yet another diversification - this time into the weaving business. The grey fabric weaving unit at Baddi (HP), commissioned in 1990 with a capacity of 20,000 meters per day has now increased to 1.5 lacs meters per day. It has already made its mark as a quality producer of Grey poplin, sheeting, shirting in the domestic as well as foreign market. This was followed by entry into fabric processing by setting up Auro Textiles at Baddi and Vardhman Fabric at Budhni,Madhya Pradesh. Today the group has 1300 shuttleless looms and has processing capacity of 115mn meters fabrics/annum. In the year 1999 the Group has added yet another feather to its cap with the setting up of Vardhman Acrylics Ltd., Bharuch (Gujarat) which is a joint venture in Acrylic Fibre production undertaken with Marubeni and Exlan of Japan. The company also has a strong presence in the markets of Japan, Hong Kong, Korea, UK and EU in addition to the domestic market. Adherence to systems and a true dedication to quality has resulted in obtaining the coveted ISO 9002/ ISO 14002 quality award which is the first in Textile industry in India and yet another laurel to its credit. YARNS Yarn Manufacturing is the major activity of the group accounting for 51.02 percent of the group turnover. Vardhman is virtually a supermarket of yarns, producing the widest range of cotton, synthetics and blended, Grey and Dyed yarns and Hand Knitting Yarns, in which Vardhman is the market leader in India. The group has twenty five production plants with a total capacity of over 10 lacs spindles, spread all over the country. In many of the yarn market segments, Vardhman holds the largest market share. Vardhman is also the largest exporters of yarn from India, exporting yarns worth more than USD 218 million. SEWING THREADS Vardhman is the second largest producer of sewing thread in the country. The sewing thread manufacturing capacity is 38 tons per day in its sewing thread plants located at Hoshiarpur, Baddi, Ludhiana, Prendurai (Tami Nadu) and Visakhapatnam. Sewing threads contributes 10.5 percent of the group turnover. FABRICS The group has created state-of-the-art fabric weaving and processing facilities in its plant at Baddi and Budhni. The group has over 1300 looms and a fabric processing capacity of 115 million meters per annum in collaboration of Tokai Senko of Japan. Fabrics business contributes 25.38 percent to the group turnover. FIBRE The group has set up an Acrylic Staple Fibre plant at Bharuch in Gujarat in collaboration with Marubeni and Japan Exlan of Japan. The plant has annual capacity of 20,000 tons per annum. Fibre contributes 4.1 percent to the total turnover of the group. STEEL The Group is also present in upper-end of the steel industry. The group has manufacturing capacity of 1,20,000 tons of special and alloy steel. The group supplies its steel products to some of the most stringent quality steel buyers like Maruti and Telco. It contributes 8.98 percent to the total turnover of the group. It's an overwhelming feeling when the efforts and hard work put in are recognized and felicitated. A feeling that galvanizes the Group into believing in more, in itself and reaffirming its commitment to offer products that invoke trust and reliability. Back home, the Vardhman Group became India's first textile company to be awarded ICO9002/ ISO 14002 Certification. It is the largest producer and exporter of yarns and Grey woven fabrics from India. Vardhman is also the largest producer of tyercord yarns and the second largest producer of sewing threads in India. The Vardhman Group vision of excellence is matched by a dedication and sincerity to be the best and excel in every industry it has a presence. ACHIEVEMENTS Textile Export Promotion Council 2012-13 Gold Trophy (Small) for the Highest Exports of Processed Yarns in Category II Gold Trophy (Small) for the Highest Exports of Bleched/Dyed/Yarn Dyed/Printed Fabrics in Category II Gold Plaque for the Highest Exports of Grey Fabrics in the Category I FIEO - Awarded in Oct. 2012 Niyat Shree Bronze Award Textile Export Promotion Council 2011-12 Silver Trophy in Processed Yarns Silver Trophy in Grey Fabrics Gold - Won Special Achievement Award in Yarn Category Textile Export Promotion Council 2010-11 Silver Trophy in Processed Yarns Silver Trophy in Grey Fabrics Textile Export Promotion Council 2009-10 Gold Trophy in Processed Yarn Category Silver Trophy in Grey Fabrics Textile Export Promotion Council 2008-09 Silver Trophy in Processed Yarn Category Silver Trophy in Grey Fabrics Textile Export Promotion Council 2007-08 Special Achievement Award in Yarn Category Textile Export Promotion Council 2007-08 Silver Top Exporter Award in Yarn Category AIM: Vardhman aims to be world class textile organization producing diverse range of products for the global textile market. Vardhman seeks to achieve customer delight through excellence in manufacturing and customer service based on creative combination of state-of-the-art technology and human resources. Vardhman is committed to be responsible corporate citizen. CHAPTER-1 COMPONENTS AND WORKING 1.1 SENSORS: A sensor is a converter that measures a physical quantity and converts it into a signal. Thermometer sense the temperature. Sensors used in this industry is proximity mechanical type. 1.1.1MECHANICAL PROXIMITY: Fig. 1.1.1: Mechanical Proximity 1.1.1.1 NPN NO TYPE: It is a dc type sensor. Two input wires at neutral and phase and output is taken at third neutral wire. Normally open means circuit is open .When fault come sensor sense. APPLICATION: In hank to cone. Fig.1.1.1.1: NPN NO Type WORKING: In hank to cone when there is fault come or thickness of thread changes due to this voltage changes,npn no sensor sense and convert it into resistance and give this information to cpu card. 1.1.1.2 NPN NC TYPE: It is also a dc type sensor.It is normally closed type.Sensor sense and when fault comes then it open its connection. APPLICATION : Link corner machine. Fig.1.1.1.2: NPN NC Type WORKING: In link corner when bobbin passes NPN NC senses when bobbin come in front of sensor ,sensor open its connection .This information is converted into resistance and give signal to plc. 1.1.1.3 PNP NO: It is also dc type three wire sensor.Two input wires are at phase and neutral ,output is taken at third neutral point.This is also normally open circuit.When fault come then it senses. APPLICATION: Gill box WORKING: To give this sensor dc voltage be converts one supply voltage from ac to dc by rectifier. NO means normally open ,it works when material passes. PNP NO means it detects the presence of nearby objects ,Without any physical contact.Till how this contact is made it works . .To give this sensor dc voltage be converts one supply voltage from ac to dc by rectifier. NO means normally open ,it works when material pass.It sense when the thickness of sliver changes, and make normally closed contact. Fig.1.1.1.3: PNP NO Type 1.1.1.4 PNP NC: It is also a dc type. But it is a normally closed type. 1.1.2 OPTICAL PROXIMITY: This is a photodiode type which generates a small curent when light energy strikes on it,or like darlington pair which allow the flow of current when light strikes on it. Fig.1.1.2: OPTICAL PROXIMITY 1.1.3 ULTRASONIC PROXIMITY: It uses the sound pulse to detect object. Fig.1.1.3: ULTRASONIC PROXIMITY 1.2 PHOTOCELL: Photocells are the devices that convert light energy into electrical energy ,by producing a voltage.A photocell is a light controlled variable resistor. Fig.1.2: Photocell 1.2.1 TYPES : 1.2.1.1REFLECTIVE TYPE: In this type emitter and receiver are in one unit.Light from emitter is transmitted in a straight line to a reflector and returns to the receiver.When target blocks the light path the output of the sensor changes.When target no longer blocks the light path the sensor returns to its normal state . EXAMPLE: In link corner machine. Fig.1.2.1.1: Reflective type emitter WORKING: In this machine when cone is completely wrapped with thread ,then it falls on the belt .When it comes in front of reflective photocell,it blocks the path between transmitter and receiver. 1.2.1.2 DIFFUSED TYPE: In this emitter and receiver are in one unit.Light from emitter strikes the target and the reflected light is diffused from the surface at all angles.When no light is reflected back to the receiver the output returns to its original state.Emitter is placed perpendicular to the target. EXAMPLE: In gill box Fig.1.2.1.2: Diffused Type WORKING: In machine light from emitter strikes but there is no target so sliver passes.When target is detected by photocell,it gives information to plc,to stop the machine and sliver passing. 1.2.1.3 THRU-BEAM TYPE: Separate emitter and receiver units are required for a thru beam sensor.The units are aligned in a way that the greatest possible amount of pulsed light from the transmitter reaches the receiver .An object (target)is placed in the path of the light beam blocks the light to the receiver ,causing the receiver’s output to change state.When the target no longer blocks the light path the receiver’s output returns to its normal state. 1.3 TRANSDUCERS: Transducer is a device which converts one form of energy to another form. Sensors are input output transducers. 1.3.1Types of transducers: 1.3.1.1 RESISTIVE TEMPERATURE DETECTOR: It is also known as PT100.It is based on the fact that resistance changes with temperature. OPERATION: An RTD is a temperature sensor that operates on the measurement principle that a material electrical resistance changes with temperature.By supply an RTD with constant current and measuring the resulting voltage drop across the resistor ,the RTD’S resistance can be calculated and temperature can be find. Fig.1.3.1.1: Resistive Temperature Detector EXAMPLE: PT100 IN LORRIS BELINI MACHINE WORKING: This machine is basically used for dyeing .In run time when temperature requirement is 90c .PLC open the steam valve and steam is rotating ,by this water is heat up.At that point PT100 required for the controlling of water heating ,that how much heating is required. 1.3.1.2 THERMOSTAT: A thermostat is a device which sense the temperature and maintained the temperature to a desired point. EXAMPLE: In transformer WORKING: In transformer through thermostat temperature is set up .For cooling or insulation oiling is done in transformer so that temperature does not exceed . Air is also pass through windings so that air heat up and windings are not heat up .When temperature increase the given value the exhaust fan automatically start up by the thermostat. Fig.1.3.1.2 : Thremostat 1.3.1.3 LOAD CELL: A load cell is a device which converts a force into electrical signal.Pneumatic load cell used in gill box.Pressure is applied to one end of a diaphragm and it escape through the nozzle placed at the bottom of the load cell.A pressure guage is attached with the load cell. EXAMPLE: Load cell in gill box machine. WORKING: Sliver is passed through two rollers , when sliver thickness changes the distance between two rollers also changes. Below sliver passing position a piston is attached ,load cell sense pressure and press piston. Then this signal sends to drive and drive give information to servomotor. Servomotor balance the thickness 1.3.1.4 POTENTIOMETER: Potentiometer is a device which is used to measure resistance by displacement. By chaning resistance voltage also changes. EXAMPLE: In link corner machine WORKING: There are three wires for supply, common,Change by knob. The range of the potentiometer is 0-500 ohm. Fig.1.3.1.4: Potentiometer 1.4 VFD( VARIABLE FREQUENCY DRIVE): It is a type of adjustable-speed drive used in electro-mechanical drive systems to control AC motor speed and torque by varying motor input frequency and voltage.There are two types of drives ac or dc.Mostly ac drives are used. 1.4.1WHY VFD IS USED ? Reduce Energy Consumption and Energy Costs: If you have an application that does not need to be run at full speed, then you can cut down energy costs by controlling the motor with a variable frequency drive, which is one of the benefits of Variable Frequency Drives. VFDs allow you to match the speed of the motor-driven equipment to the load requirement. There is no other method of AC electric motor control that allows you to accomplish this. Additionally, the utilization of VFDs improves product quality, and reduces production costs. Less time consuming then previous system In previous systems when we want to change the speed of motor ,we change pulley . It is difficult to change pulley and it is time consuming.By pulley we change motor speed in steps only like 60 or 70 not between like 65. Extend Equipment Life and Reduce Maintenance Because of the VFDs optimal control of the motor’s frequency and voltage, the VFD will offer better protection for your motor from issues such as electro thermal overloads, phase protection, under voltage, overvoltage, etc.. When you start a load with a VFD you will not subject the motor or driven load to the “instant shock” of across the line starting, but can start smoothly, thereby eliminating belt, gear and bearing wear. It also is an excellent way to reduce and/or eliminate water hammer since we can have smooth acceleration and deceleration Process: In ac drives there are two card In power card ac to dc and dc to ac conversion take place. In control card there are two inputs analog and digital input .Analog input is vary with refrence voltage. When motor works it follow these Acceleration Deacceleration Lsp Hsp Current MOTOR PARAMETERS: Frequency Voltage RPM Current 1.4.2 WORKING: In ac motor ac supply is given,but if we want to vary motor speed we only vary dc voltage. so we have to convert first ac to dc voltage by the combination of diodes.It works like a rectifier. Thermistors are used in motors to control temperature. After conversion dc voltage have some amount of ac voltage .We use combination if LC filter to completely rectify the ac from dc voltage. This rectified dc voltage is variable .At IGBT gate pulse is given, by transistor switching on off many times or pulse triggering ,frequency of pulse changing .Hence motor speed also changes. After that we converts this dc voltage into ac voltage by IGBT. Fig.1.4.1: Motor Working CHAPTER - 2 DYE HOUSE 2.1 INTRODUCTION: Dye house is the unit of worsted unit only. Dying of the hanks take place here and the process is termed Hank Dyeing. The machine used in this is Loris Bellini – Leonardo 600 MC3 60Kg IN13112. 2.2 PROCESS FLOW Fig.2.2: Process Flow 2.2.1 FILLING : This is the process of filling the tank with water. There are to options of adding water 1. Cold and 2. Hot water. Two valves operate this function and this is controlled with a PLC along with the Display unit. When input is given through the display unit the PLC supplies this to the Solenoid Valve that uses air output for functioning. Water level Sensor senses the level of water and works on the basic pressure sensing principle. As the tank gets full of water then pressure increases in valve and gives the corresponding reading in cm. Maximum level being 290 cm. When pressure is applied Resistance changes and corresponding current changes which is evaluated by PLC. 2.2.2 Bulking: In this stage the machine is kept idol for 30 mins with the material inside. 2.2.3 Chemical Injection: There is an additional tank behind the machine to mix colored and dyed water. Water sensors are present that sense the level of water in this tank. It consists of a motor and pneumatic valve is in series. As the motor is in ON stage the Pneumatic Valve opens and when the motor is OFF , the valve closes. 2.2.4 Run Time: During this stage the temperature increases from 85° C to 99°C. Temperature sensing is carried out by PT 100. This heating process is carried through a coil which is operated by a steam valve controlled by PLC. PLC opens the stream valve and steam runs through a coil which is kept in contact with water. As hot steam passes the coil the tube gets heated up and as a result the water gets heated up. 2.2.5 Hold Time: Temperature is maintained at 99°C. 2.2.6 Overflow: This process controls the overflow of water by using Cold water valve and Hot water valve. Hot water valve controls the overflow of hot water out of the tank from up meanwhile, the cold water valve controls the inlet of cold water which is injected from below. This process is carried till the temperature becomes 50°C. 2.2.7 Drain: This final stage is when all the water is drained. 2.2.8 Hydro-extractor : This machine is used to dry the dyed hanks. This uses the basic principle of the dryer2.3 LORIS BELLINI: The components or devices used in the process are explained in detail below: 2.3.1 PT100 : The principle of operation is to measure the resistance of a platinum element. The most common type (PT100) has a resistance of 100 ohms at 0 °C and 138.4 ohms at 100 °C. There are also PT1000 sensors that have a resistance of 1000 ohms at 0 °C. The relationship between temperature and resistance is approximately linear over a small temperature range. This is used in the dyeing machine to sense the temperature of water in the tank which should be 85° C initially and 99°C finally. Fig.2.3.1: PT100 2.3.2 Water Level Sensor: Liquid level can be determined in the machine using a water level sensor by taking a continuous pressure measurement from the bottom of the tank. The pressure existing at a certain depth within a liquid is directly proportional to the column of liquid above above it (measured as Water Column or WC). The pressure at the bottom of the tank or body of liquid (WC) is related to the height of the liquid and corresponding reading is obtained. Fig.2.3.2: Water level sensor 2.3.3 Human Machine Interface (HMI): A Human Machine Interface (HMI) is exactly what the name implies; a graphical interface that allows humans and machines to interact. For a manufacturing line to be integrated with an HMI, it must first be working with a Programmable Logic Controller (PLC). It is the PLC that takes the information from the sensors, and transforms it to Boolean algebra, so the HMI can make decisions. The greatest advantage of an HMI is the user-friendliness of the graphical interface. The graphical interface contains color coding that allows for easy identification (for example: red for trouble). Pictures and icons allow for fast recognition, easing the problems of illiteracy. HMI can reduce the cost of product manufacturing, and potentially increase profit margins and lower production costs. HMI in Loris Bellini is the Display unit as shown below Fig.2.3.3: HMI Block Diagram Fig.2.3.3: HMI Display 2.3.4 PLC (Programmable Logic Controller): A Programmable Logic Controller, PLC or Programmable Controller is a digital computer used for automation of machinery. PLCs are used in many industries and machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. The PLC performs the logic functions of relays, timers, counters and sequencers. Loris Bellini also uses PLC to automate the working and uses a display unit for the same , explained in the next section. Fig.2.3.4: PLC 2.3.5 Solenoid Valve: A solenoid valve is an electromechanical device used for controlling liquid or gas flow. The solenid valve is controlled by electrical current, which is run through a coil. When the coil is energized, a magnetic field is created, causing a plunger inside the coil to move. Depending on the design of the valve, the plunger will either open solenoid valve pictureor close the valve. When electrical current is removed from the coil, the valve will return to its de-energized state. In direct-acting solenoid valves, the plunger directly opens and closes an orifice inside the valve. In pilot-operated valves (also called the servo-type), the plunger opens and closes a pilot orifice. The inletline pressure, which is led through the pilot orifice, opens and closes the valve seal. The most common solenoid valve has two ports: an inlet port and an outlet port. Advanced desigs may have three or more ports. Some designs utilize a manifold-type design. Solenoid valves make automation of fluid and gas control possible. Modern solenoid valves offer fast operation, high reliability, long service life, and compact design. Fig.2.3.5: Solenoid Valve . 2.3.6 Variable Frequency Drive (VFD): A Variable Frequency Drive (VFD) is a type of motor controller that drives an electric motor by varying the frequency and voltage supplied to the electric motor. Other names for a VFD are variable speed drive, adjustable speed drive, adjustable frequency drive, AC drive, microdrive, and inverter. Frequency (or hertz) is directly related to the motor’s speed (RPMs). In other words, the faster the frequency, the faster the RPMs go. If an application does not require an electric motor to run at full speed, the VFD can be used to ramp down the frequency and voltage to meet the requirements of the electric motor’s load. As the application’s motor speed requirements change, the VFD can simply turn up or down the motor speed to meet the speed requirement. Fig.2.3.6: VFD 2.3.7 Air Piston (Pressure of 300 mm): Air Pistons are mechanical devices which use the power of compressed gas to produce a force in a reciprocating linear motion. Like hydraulic cylinders, something forces a piston to move in the desired direction. The piston is a disc or cylinder, and the piston rod transfers the force it develops to the object to be moved.It is preferred to use these because they are quieter, cleaner, and do not require large amounts of space for fluid storage. Once actuated, compressed air enters into the tube at one end of the piston and, hence, imparts force on the piston. Consequently, the piston becomes displaced (moved) by the compressed air expanding in an attempt to reach atmospheric pressure. Fig.2.3.7: Air Piston CHAPTER-3 GILL BOX 3.1 INTRODUCTION: GILL BOX is a machine which is used for drafting .This machine increases the strength of material by drafting. It converts the six can into two can by drafting. In this machine basically counter meter is used ,which counts the length of material .Autolevellor controls the thickness of the material. Fig.3.1: Introduction 3.2COMPONENTS USED IN MACHINE : Fig.3.2:Components 3.2.1 INPUT SUPPLY : The input supply used is three phase supply(440v).Three phase supply with four wires red, yellow, blue, green (for earth). 3.2.2 FUSE: It interrupts excessive current(blows)so that further damage by overheating is prevented fuse is used. It automatically trip down ,so there is no harm to machine.It is a type of low resistance. Fuses are used: • For Indication lamps • For control circuit • Main motor • Suction motor • Spraying motor • Blowing motor • For 220v ac Fig.3.2.2: Fuse 3.2.3 MPCB: Motor protection circuit breaker is used for the protection of motor against short circuit and overload. FUNCTIONS: • Short circuit protection • Overload protection • Line protection • Phase loss protection • Rated current adjustment There are five MPCB used in this machine: • Suction motor(2.4 kw) • Blowing motor(0.75 kw) • Spray motor(0.55 kw) • Main motor(7.5 kw)(2 mpcb) • Transformer(2) Fig.3.2.3: MPCB 3.2.4 CONTRACTOR: There are number of contactor used in this machine. These contactors are used for connection of power. These are a type of relay that can handle the high power required to directly control an electric motor or other loads. 3.2.5 MAIN MOTOR: The voltage range of main motor is 380-420v.In this machine three phase supply is used .We convert 440v to 220v by step down transformer. This voltage step downs is divided for three wires. This supply is ac .There are three voltage ranges 220v, 24v, 24v. The 24v supply is converted into dc 24v supply by rectifier. 3.2.6 RELAY: A relay is an electrically operated switch .Relays are used wher it is necessary to control a circuit by a low power signal, or where several circuits must be controlled by one signal. In this machine relays are used for safety purpose.By connections giving input to plc and plc stop motor automatically when door open .There are two relays used for low speed and for high speed. 3.2.7 CONNECTOR: For three phase supply there are three wires. Red and blue are input wires. Black is output. • Red : This wire is for 24v and 220v ac supply. • Blue: This wire is for 24v dc supply. • Black: This wire is for 24v ac or 24 v dc supply. 3.2.8 VFD: Variable frequency drive. The main function of vfd is by changing frequency voltage changes. It is used because it is less time consuming and energy saving device. In drive first ac voltage is concerted into dc voltage. Filters rectify the ac voltage completely from this dc .Then this dc voltage is varying by changing frequency. IGBT converts this dc voltage into ac voltage.The vfd used in this machine is DELTA vfd .Mainly ac drives are used. This drive is connected with motor. Frequency of vfd used in this machine is 33hz. Power of this vfd is 7.5kw/10hp.Voltage is 460v.This is a 3 phase supply. 3.2.9 DISPLAY: In this there are three switches on,off,inch. There is a device counter meter which counts the length of material. Through connections to plc length is given to plc. When that length completes sensor send information to counter and machine stops. Fig.3.2.9: Display 3.2.10 SENSOR: Sensor used in this is proximity type pnp no.PNP means input is at positive and negative and at positive is used for output. This is dc type sensors.To give this sensor dc voltage be converts one supply voltage from ac to dc by rectifier. NO means normally open ,it works when material passes. When due to sliver there is jam in machine then metal is come in front of sensor ,it sense and give information to plc. PNP NO means it detects the presence of nearby objects ,Without any physical contact.Till how this contact is made it works . Fig.3.2.10: Sensor 3.2.11 RESISTANCE AND DIODE: In contractor after supply off ther is still some voltage present,the combination of resistance and diode protect contractor from this. 3.2.12 DIODE : The diode is used to protect plc.This is used for not giving reverse voltage to plc. 3.2.13 TIMER: Timer used in gill box is timer off delay.It is a type of timer that delays turning off. It works by immediately closing contacts when the control solenoid is energized and then waits for a specified period of time to open them after power is removed from the coil.The contacts transfer on time out,to reset,close the control input prior to time out. Fig.3.2.13:Timer off 3.2.14 AUTOLEVELLOR: Autoleveller is an additional device which is meant for correcting the linear density variations in the delivered sliver by changing either the main draft or break draft of the drafting system, according to the feed variation. There are two types of Autolevelling systems. They are • Open loop system • Closed loop system Most of the drawframe autolevellers are open loop auto levellers. In open loop autolevellers, sensing is done at the feeding end and the correction is done by changing either a break draft or main draft of the drafting system. In closed loop system, sensing is at the delivery side and correction is done by changing either a break draft or main draft of the drafting system. Most of the earlier card autolevellers are closed loop autolevellers. Both closed loop and open loop systems are being used in such autoleveller Open loop system is very effective, because the correction length in open loop system is many folds lower than closed loop system. But in case of closed loop system, it is confirmed that the delivered sliver is of required linear density. In case of open loop system, since the delivered material is not checked to know whether the correction has been done or not, Sliver monitor is fixed to confirm that the delivered sliver has the required linear density. Let us discuss about an autoleveller system which is being used in most successful drawframes like RSB-951, RSB-D-30 etc. In gill box open loop system used.This system is an electronic levelling system. The major components in the system are scanning roller signal converter levelling CPU servo drive (servo motor and servo leveller) Differential gear box (Planetary gear box).Function of the scanning roller is to measure the variation in the feed material. All slivers fed to the machine pass through a pair of scanning rollers. One of the scanning rollers is moveable. These scanning rollers are loaded either by a spring loading system or a pneumatic loading system. Pneumatic loading is always better, because the pressure in kgs will be always same (consistent), irrespective of the sliver feed variation. But in the case of spring loaded, the pressure on scanning rollers may vary depending upon the feed variation. The variations in sliver mass of the incoming slivers displace the scanning roller. The distance moved by the scanning is proportional to the sliver mass fed. This displacement of scanning rollers is transformed into voltage by a signal converter and is fed to an Electronic Levelling processor. With analogue system, electronic levelling processor is a servo amplifier, but in the case of digital system, it a CPU. It is the Electronic Levelling processor which furnishes the correct target value to the servo drive. As the thickness of the sliver changes voltage changes accordingly. Then servomotor adjust the thickness of sliver . 3.2.15 PHOTOCELL: In gill box photocell sense the sliver.The photocell used in gill box is diffused type.In this case the light source and the photosensitive element are included in the same unit.The emitted light reaches the photosensitive element after being reflected from an object present in the irradiation field.The presence or absence of light cause changes in the output state. Diffused type photocell sense when an object comes and it does not sense sliver. This is a ac type sensor. Fig.3.2.15: Photocell 3.2.16 PLC: Programming logic controller. All steps are performed by plc by converting voltage ,displacement etc into resistance. In autolevellor the distance of scanning rollers is directly proportional to sliver mass.Then displacement of scanning rollers are converted into voltage by a signal converter .This voltage sense by plc, and according to that thickness maintained. PLC inputs in this machine are like • Autolevellor safety • Stopping gill box • Without autolevellor • Electrovalve for threading right and left side • Electrovalve for spraying at creel • Main pressure switch. • Emitters and receivers for stop motion at delivery 3.2.17 LOAD CELL: A load cell is a converter that converts a force into electrical signal. It is used in the gill box machine .Sliver is passed through two rollers , when sliver thickness changes the distance between two rollers also changes. Below sliver passing position a piston is attached , load cell sense pressure and press piston. Then this signal sends to drive and drive give information to servomotor. Servomotor balance the thickness. 3.2.18 CREEL AND ROLLER: From can sliver is placed on roller and roller rotates ,when sliver cut down it stops. Fig.3.2.18: Creel and Roller CHAPTER-4 PROCESS FLOW OF MACHINES In whole process main purpose is drafting. Drafting=no. of cans*wrapping(weight of i/p can in 1 m)/weight of o/p can in 1 m 4.1 SEYDEL MACHINE: In worsted unit firstly starting from seydel machine.Input material of seydel machine is tow,which is prepare from vardhman mill in gujrat.In seydel machine drafting is done .For this purpose three pulleys are used .Speed of each one is more than previous one.This is for drafting.Material is pass through machine at very high temperature.At the output sliver comes out. Fig.4.1: Seydel 4.2 REBREAKER: In this machine input is sliver which comes out from seydel and output is tops.It uses 20 approximately cans from seydel and make two cans ,by drafting. Fig.4.2: Rebreaker 4.3 GILL BOX: After rebreaker material tops in the form of cans are given to gill box as input.There are three gill box machines used For gill box1: Drafting=8*20/26(1)=6.1 For gill box 2: Drafting= 6*26/24=6.5 For gill box 3: Drafting=24*3/11=6.01 Fig.4.3:Gill Box 4.4 FM7: In this machine roving is input and yarn bobbin is output which is of 230-260mg. Fig.4.4:FM7 4.5 RING FRAME: In this machine FM7 output is given as input and output is bobbin of 80-95g.In this machine sensors are used so that when bobbin is fill then it automatically move to link corner machine. Fig.4.5:Ring Frame 4.6 LINK CORNER: In this input is bobbin from ring frame machine and a cone is prepare at the output which is 2-3kg.This material is single packing material. Fig.4.6: Link Corner 4.7 CHEESE WINDING: In this two cones are used and material prepare is double thread .This is done on the requirement of material. 4.8 TWO FOR ONE: In this the double thread which is prepare from the cheese winding is twisted to make one .It is called so because it twist two thread and make one. Fig.4.8: TFO 4.9 REELING: In this machine from the twisted thread from tfo hanks are made. Fig.4.9: Reeling 4.10 DYEING : In this the dyeing of the hanks done based on the requirement of the color material.For this we use automatical dyeing machines. After that dyeing material is dryer in machine. 4.11 HANK TO CONE: In this the coloured hanks are converted into cones. 4.12 PILOT: This machine is used for the packing purpose.