Dyeing Machine Control System

A

PROJECT REPORT

ON

DYEING MACHINE CONTROL SYSTEM

FOR

VIBRONICS PRIVATE LIMITED

SUBMITTED BY

KAMBLE MANOJKUMAR SANTRAM

MBA (2005-2007)

IN PARTIAL FULFILLMENT OF

MASTERS DEGREE IN BUSINESS ADMINISTRATION

UNIVERSITY OF PUNE

THROUGH

VISHWAKARMA INSTITUTE OF MANAGEMENT PUNE

2

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

3

CONTENTS

S. No. TOPIC PAGE NUMBER

1. EXECUTIVE SUMMARY 1

2. OBJECTIVE AND SCOPE

2

3. COMPANY PROFILE 3

4. EXISTING SYSTEM &

NEED OF THE SYSTEM 20

5. OPERATING ENVIRONMENT

21

6. PROPOSED SYSTEM

22

9.

REQUIREMENT DETERMINATION TECHNIQUES

23

10.

SOFTWARE ENGINEERING PARADIGM

24

11. WORKING OF DYEING MACHINE CONTROLLER

33

12. RUNTIME FORMS

45

13. TESTING PROCEDURE & IMPLEMENTATION PHASES

68

14. LIMITATIONS 70

15. PROPOSED ENHANCEMENT

71

16. CONCLUSION 72

17. BIBLIOGRAPHY 73

4

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 Dr. Vandana Gote Director VIM Project Guide

5

EXECUTIVE SUMMARY

Introduction:-

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.

6

.

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.

7

Company Profile:-

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.

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

8

processes, they include: -

Ø The louder the cleaner the better

Poor insulation or a low frequency system maybe the main cause of loudness.

Ø The quiter the cleaner the better

Higher frequency operation and good insulation may lead to quitness.

Ø 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: -

9

· 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.

10

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

11

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

12

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

13

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

Ø Complements industrial cleaning process

Ø Provides high intensity cleaning action with optimum efficiency

Ø Economical, safe and compact procedure

Ø Specially designed for rapid and thorough cleaning of small and large

components and assemblies

Ø Results in efficient cleaning of metal, plastic, ceramic, alloys etc.

Ø Usable with high temperature detergents, for derusting, decarbonising,

descaling etc.

Ø Greater efficiency with high intensity cleaning.

Ø Rigorous cleaning of intricate parts that are normally inaccessible

14

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

15

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:-

Ø Effective condensation and water separation

Ø Heat insulation

16

Ø Digital controllers

Ø Vigorous vapour generation chambers

Ø Low/high level central with alarm

Ø 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.

17

Technical specifications for FD 301 M, FD 301 MP, FD 401 MP

Frequency range 0.5 MHz to 12 MHz

Vertical Linearity + 2%

Gain 140 dB

Gain control 80 dB in Steps of 2

dB + 6 dB stepless

Depth range Upto 5 mtrs in steel

Delay 3 mtrs of steel

Ranges provided 1,5,10,50,100 cms

with a multiplying

factor of 5

Time base linearity Better than 1%

PRF Variable from 1 KHz

to 125 Hz interlinked

with range

Display 70 x 55 mm

Operating

temperature

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.

18

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.

19

Fig :- Ultrasonic Flaw Detectors

20

Ultrasonic Processors

It 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 ½"

· Model VPL-P2 of power 250 watts & dia 1"

21

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

22

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

23

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

24

Existing System and Need for the System

Existing System

Dyeing 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 System

In 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.

25

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 : Pentium 2.8 MHz.

RAM : 128 MB.

Hard Disk : 20 GB.

Micro- controller : LPC

2141.

Protocol : RS- 485.

The following are the Recommended hardware configuration work

without any problem in a long run.

Processor : Pentium III 2.8MHz.

RAM : 256 MB.

Hard Disk : 20 GB.

Micro- controller : LPC 2141.

Protocol : RS- 485.

26

Proposed System

Objectives 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.

27

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 anticipation, requirement investigation, and

requirement specification.

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.

28

SOFTWARE ENGINEERING PARADIGM

[DATA FLOW DIAGRAMS & FLOW CHARTS]

29

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

Print

Machine Parameter

Machine Configuration Create

New

Recipe

List

Of

Recipe

Recipes

Data History

OEM Properties

Micro Controller

Dyeing Machine

Machine Timers

30

Fig :- Data Flow Diagram of working of the MIMIC Control Panel

ADD TANK STOCK TANK

MVAT1 FILLING

MVAT2 RINSING

MVAT

MVAT3 HT DRAIN

MVAT4 OV. CIRC.

MVAT5 LT DRAIN

MANUAL

Select Tank

MVAT6 OPEN

MVAT7 P.F.REVERSE

ADD TANK1 MAIN VAT

ADD TANK5 MIX & HEAT

ADD TANK3 DOSING

ADD TANK4 TANK CLEAN

ADD TANK2 INJECTION

STOCK TANK1 FILL

STOCK TANK2 MIX HEAT

STOCK TANK3 MAIN VAT

STOCK TANK4 MAIN STOCK

STOCK TANK6 P.F.REVERSAL

Select Process Select

Process Select Process

ADD TANK6 FILL

STOCK TANK5 TANK CLEAN

A B

C

D

E

A B

A A

A C

A D

A E

A F

C A M

A G

C A N

C A O

C A P

C A Q

C A R

C A S

C A T

C A U

C A V

C A W

C A X

A YA Z

A Z1

MVAT10 HEAT&RUN

MVAT11 SQUEEZE

MVAT8 PRESSURI.

MVAT9 DEPRESSURI.

H

I

J

K

MVAT12 SHOCK RINSE

J

31

FLOW CHARTS OF DIFFERENT PROCESSES

A

WATER LEVEL

ENTER LEVEL

PRESS START P/B

HOT COLD

Y

1) MVAT FILLING 2) MVAT RINSING

RINSING COOLING

B

WITH WITHOUT COOLING

ENTER TARGET

ENTER RINSE TIME.

ENTER CIR.

.

RINSE TYPE HOT/CO

COLD HOT

ENTER TARGET

PRESS

Y

DRAIN TYPE

PRESS START P/B

HT DRAIN

Y

C

EFFLUENT DRAIN

3) MVAT HT DRAIN

D

ENTER TIME

PRESS START P/B

Y

4) MVAT OVERFLOW CIRCULATION

32

E

ENTER LEVEL

PRESS START P/B

Y

5) MVAT LT DRAIN

F

PRESS START P/B

Y

6) MVAT PREPARE TO OPEN

G

ENTER FWRD. TIME

PRESS START P/B

Y

ENTER REVERSE

TIME

ENTER PUMP SPEED

ENTER PRESSUR

CONTRL.

ENTER FLOW CONTRL

7) MVAT PUMP FLOW REVERSAL 8) MVAT PRESSURISATION

H

ENTER PRESSURE LIMIT

PRESS START P/B

Y

33

9) MVAT DEPRESSURISATION

I

ENTER RESSURE LIMIT

PRESS START P/B

Y

J

ENTER TEMP

PRESS

Y

ENTER GRADIENT

ENTER HOLD TIME

10) MVAT HEAT &RUN

K

ENTER NO. OF CYCLES

PRESS START P/B

Y

11) MVAT SQUEEZE

L

ENTER TIME

PRESS START P/B

Y

12) MVAT SHOCK RINSE

34

HOT

M

ENTER LEVEL

PRESS START P/B

Z

1) AD1 MAIN TO ADD TANK

N

PRESS START P/B

Z

2) AD INJECTION

ADD LEVEL PROBE

PROBE=1

ENTER CURVE NO.

ENTER QUANT-ITY

ENTER TIME.

HOT

ENTER CLOSE TIME

PRESS START P/B

Z

O

PROBE=0

ENTER OPEN TIME

3) AD DOSING

P

PRESS START P/B

Z

4) AD CLEAN

35

Q

ENTER MIX VALUE

PRESS START

P/B

Z

ENTER TIME

ENTER TEMP

5) AD MIX & HEAT

R

ENTER LEVEL

PRESS START P/B

Z

6) AD ADD FILL

S

WATER LEVEL HOT/COLD

ENTER LEVEL

PRESS START P/B

HOT COLD

Z1

1) ST FILL

T

ENTER MIX VALUE

PRESS START P/B

Z1

ENTER TIME

ENTER TEMP

2) ST MIX & HEAT

36

U

ENTER

LEVEL

PRESS START P/B

Z1

3) ST MAIN TO STOCK TANK

V

ENTER LEVEL

PRESS START P/B

Z1

4) ST STOCK TO MAIN VAT

w

PRESS START P/B

Z1

5) STOCK TANK CLEAN

X

ENTER FWRD. TIME

PRESS START P/B

Z1

ENTER REVERSE TIME

ENTER FLOW ONTROL

ENTER DIFF. PR. FWD.

ENTER FLOW CONTROL

6) ST PUMP FLOW REVERSAL

37

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.

38

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

39

Sensors to sense the physical parameters

Physical Parameters Sensor Output Type

Temperature Analog 0 to 5 V

Pressure Analog 0 to 5 V

Production Rate Digital 116 pulses / sec

Energy Consumed Digital 0.3 Hz

Machine On/Off Status Digital 100 Hz

Physical Parameter Digital Value Bytes Required

Temperature 10 Bits 2 Bytes

Pressure 10 Bits 2 Bytes

Production Rate 16 Bits 2 Bytes

Energy Consumed 8 Bits 1 Byte

Machine On/Off Status 1 Bit 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.

40

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

frame

Device

ID

Source

ID

Functio

n Code

Data

Count

Data Check

Sum

End of

frame

NULL

\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)

41

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).

42

Scientific Diagram of Dyeing Plant (1)

Fig:-Scientific Diagram of Dyeing Plant (1)

43

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.

44

Form: MIMIC Control Panel Tester (Before Working)

45

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.

46

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,

47

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.

48

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.

49

RUNTIME FORMS

50

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.

51

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

52

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.

53

Machine Recipe

4) 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.

54

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.

55

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 Icon Description

Filling

To perform the filling operation to the Main Vat Tank.

Heat and Run

It perform the Heat and Run operation in the Main vat Tank.

HT Drain

It performs the HT Darin operation in the Main Vat Tank.

LT Drain

It performs the LT Darin operation in the Main Vat Tank.

MV

Circulation

It performs the Main Vat Circulation operation.

Prepare to

Open

It performs the Prepare To Open The Main vat Tank.

Pressurization

It performs the Pressurization operation In the Main Vat tank.

Pump Flow

Reversal

It performs the Pump Flow Reversal operation in the Main

Vat Tank.

Rinsing

It perform the Rinsing of Water in The Main Vat Tank

Squeezing

It performs the Squeezing Operation In the Main Vat Tank.

MV Steaming

It performs the Main Vat Steaming.

56

2. Add Vat Tank

3. Stock Tank:-

User Authentication :-

This Part consist of

1. Supervisor Id

2. Machine Number

Processes Icon Description

Filling

To perform the filling operation to the Add Vat Tank.

Heat and Run

It performs the Heat and Run operation in the Add Tank.

Dosing

It performs the Dosing operation in the Add Tank.

Injection

It performs the Injection operation in the Add Tank.

MV To Add

Tank

It perform the operation of the transfer the Mixture from Add

Vat to Main Vat Tank

Cleaning

It performs the Cleaning operation in the Add Tank.

Processes Icon Description

Filling

To perform the filling operation to the Stock Tank.

Heat and Run

It performs the Heat and Run operation in the Stock Tank.

MV To Stock

It performs the transfer mixture MV to Stock operation.

Stock To MV

It performs the transfer mixture Stock to MV operation.

Cleaning

It performs the Cleaning operation in the Stock Tank.

57

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.

58

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.

59

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

60

OEM Parameters

8) 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

61

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.

62

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.

63

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.

64

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.

65

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.

66

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.

67

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.

68

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.

69

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

70

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.

71

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.

72

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.

73

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.

74

Drawbacks and Limitations

Since it is an SSI unit, the promoters will be responsible for

commercial and its technical growth.

75

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.

76

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

77

Bibliography

Author : Steven Hulzner

Title of Book : V.B. 6.0 Programming Black Book

Edition/ Year : 30th Edition

Name of the : Dream Tech

Publisher

Author : Ebangelos Patroness

Title of Book : Mastering V.B. 6.0

Edition/ Year : 1st Edition

Name of the : BPB publication

Publisher

Author : James Axelxon

Title of Book : Serial port complete

Edition/ Year : 3rd Edition

Name of the : Pen Ram International

Publisher

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