Loop Length/Production DAQ System Server RS-485 to RS-232 Converters KnitForce KnitForce Software
Loop Length/Production DAQ System (LLM) 1. LLM would be fixed on each Knitting Machine 2. Each LLM would have connections as follows 1.Encoder that is fixed on each Yarn Storage Feeder 2.In case you require to monitor 2 belts, then 2 counters & Encoders 3.Proximity Sensors – 1.To count rotations 2.Measure RPM 3.Identify RUN/Stop condition 4.Automatic Inputs from knitting machine 1.Yarn Stoppage (From Knitting Machine 2.Broken Needle (From needle detector in Knitting Machine) 3.Doff Stop (From Relay output on Knitting Machine) 4.Press Off /Set Off (From knitting Machine (Single Jersey Only) 5.Automatic Machine Stoppages 1.Over Speed 2.Incorrect yarn feed beyond tolerance level
Setting the machine metrics to the meter manually before installation After installation, the meter continues to display the loop length value of the knitted fabric per CAM rotation As the meter has an eye on this loop length value, it will turn off the machine when this value deviates from the standard one After the appropriate knitting machine changes are made, the machine can be turned on again manually The meter constantly monitors the needle break and yarn cut in the machine and will communicate this detail to the ERP. The number of revolution of the feeder encoder per CAM rotation and the number of rotations of CAM per minute gets calculated in the meter and can be checked at any point of time by pressing appropriate keys.
Loop Length Meter and Data Acquisition System Micro-controller based System Loop Length measurement is based on proximity sensor (sensing the CAM rotation) and rotary encoder (sensing feeder rotation) RS-485 Communications to Server Measures the loop length & sends the information to server Keypad interface to make appropriate setting to the meter in case of varied work flow Reasons for Stoppage can also be identified through keypad interface A SPST Relay is used to turn off the knitting machine when a varied loop length is identified Lamp indication for yarn cut and needle break conditions Inbuilt memory backup of information in case of power failure Seamless half duplex communication to server SMPS based power supply
Server A separate server is required to store following Production Information Fabric Inspection & Defect Analysis System (FIDAS) SMS Alerts Shed Defect Alert Display Shed Production & Efficiency Display
KnitForce KnitForce Software Automatic Feed from ERP & Inhouse Software Customized Product Development for Valli Textiles Integration with FIDAS Integration with Shed Display Systems Every day Production SMS alerts Developed in VB. Net & MS SQL backend
■ KnitForce Software Color Coding provides the management team a real-time overview of production status, with immediate drill down capability to an individual machine/style/operator ■ The KnitForce Software allows flexibility for custom reporting for additional productivity enhancements and options ■ The KnitForce Software allows the department management team to view overall downtime occurrences to minimize opportunities lost ■ The KnitForce Software can integrate downtime and revolution information with other internal systems and facilitating pay for performance
► Prevents Overfeeding and Underfeeding—both lead to poor quality fabric ▪ Overfeeding causes a porous fabric that has loops, which will shrink and use excess yarn ▪ Underfeeding produces a heavy, dense and narrow fabric, and also wastes yarn ► Allows strict tolerances to be maintained ► Time spent on periodic audits can be eliminated ► Reduction of unnecessary dying and finishing of off quality fabric ► Allows you to detect off quality yarn leading to requests from vendors for higher quality yarn ► Reduces time lost (extra labor and downtime) dealing with poor quality fabric Utilizing this yarn rate control system even minimal % of adjustment would lead to greater profits on yarn consumption.
Machine# Current Status Shift Production Shiftwise Utilization Shift Wise Efficiency Yarn Rate Consumption (Loop Length) Style Wise Production Employee Production, Utilization, Efficiency Stoppage Report
REAL TIME PRODUCTION MONITORING SYSTEM - DASHBOARD ALL MACHINES STYLE PLANT INFO QUALITY PRODUCTI ON REPORTS ALL KNITTERS Shed No/M C Eff % Total Prod 1/2387.4521225 2/1789.0012567 3/1097.875665 484.43 5 6 7 8 9 10 11 12 13 14 15
REAL TIME PRODUCTION MONITORING SYSTEM - DASHBOARD ALL MACHINE S STYLE PLANT INFO QUALITY PRODUCTI ON REPORTS ALL KNITTERS Shed / Kniter Eff % Total Prod 1/Kumarvel87.451225 1/Sundar89.002567 397.875665 484.43 5 6 7 8 9 10 11 12 13 14 15
REAL TIME PRODUCTION MONITORING SYSTEM - DASHBOARD ALL MACHINE S PLANT INFO QUALITY PRODUCTI ON REPORTS ALL KNITTERS STYLE Style/Work Order# Plan Actual 1234/50024561225 2323/34534452567
REAL TIME PRODUCTION MONITORING SYSTEM - DASHBOARD ALL MACHINES STYLE PLANT INFO PRODUCTI ON REPORTS ALL KNITTERS To be Decided
REAL TIME PRODUCTION MONITORING SYSTEM - DASHBOARD ALL MACHINES STYLE PLANT INFO QUALITY ALL KNITTERS REPORTS To be Decided
3 rd Party Energy Monitoring System can be integrated with existing Software Meanwhile we shall arrange for a quote form our associate partner for energy monitoring system
Current Shift Efficiency Machine Detail Piece Auto Downtime Detail Auto-Downtime Downtime Detail – Downtime Declaration Stops Report Knitter Shift Style Production