HINDUSTAN ENTERPRISES.
Coimbatore, Tamil Nadu -641004.
Web: www.hindustansystems.com
Lanline: 0422-2578990
Mob : 96262 66990, 98438 66990
CONVENTIONAL SYSTEM
CONVENTIONAL SYSTEM
SCHEME
Disadvantages:
Open Loop Control
No Feedback from the output
The Quality is not constant
CONVENTIONAL SYSTEM
DRAWBACKS
Lickerin, Doffer Drive, Calendar Roll, Flats, Feedroll are
driven by same motor which results in motor overload and
high power consumption
Frequent Mechanical Maintenance of Doffer & Feedroll drive
To Change the hank its required to change the
draft Changing Gears
Doffer Gears to be changed for changing the Doffer Speed.
Lot of Contactors are required for effective stop motion which
makes electrical maintenance very tough
No Autolevelling & Production data Monitoring
SCHEME OF PROPOSED
SYSTEM
Advantages:
Open Loop Feedback Control
Feedback from Output through Autolevelling Sensor
The Desired Quality Can be Achieved
MECHANICAL
ELIMINATIONS
Doffer Side
Doffer Slow Fast Gear Box Assembly and bearing
96T Gear, 62/30 Gear, 80 T Gear, Production Gear, Main Drive Shaft
with Gear and Bearing
Electromagnetic Clutch worth, Gear Plates, Stud and all Bearing
Accessories, solenoid Valve for Gear Box, Break for Gear Box
MECHANICAL
ELIMINATIONS
Doffer Slow Fast Gear Box Assembly
with Electromagnetic Clutch
MECHANICAL
ELIMINATIONS
96T Gear, 62/30 Gear, 80 T Gear, Production Gear
MECHANICAL
ELIMINATIONS
Feedroll Side
Feedroll Drive Shaft with Worm Gears and Drafting Change Gear
Webdoffing Side
Three Crush roller assembly
Table Calendar Roller
All Gear Drives Connected to Doffer Drive
Total Cost Savings in Spares
Rs.25,000
MECHANICAL
ELIMINATIONS
Gears for driving Calendar Roller
MECHANICAL
ELIMINATIONS
Crush Roller & Calendar Roller Assembly
ELECTRICAL
ELIMINATIONS
Solenoid Coil for Doffer Drive Slow Fast Gearbox Break
Stop Motion Contactors Including Double Lap, Crushroll Lapping,
Sliver Breakage, Can Changer, Doffer Slow Fast etc
Fuses, Old Wiring, PVC Channels, Old Connectors
Length Counter, Hour Meters will be removed
ELECTRICAL
ELIMINATIONS
Electrical Panel of C1 Series Carding Machines
DOFFER SIDE MECHANICAL
ALTERATIONS
Doffer Section Before and After Conversion
WEBDOFF MECHANICAL
ALTERATIONS
Webdoff Section Before and After Conversion
FEEDROLL MECHANICAL
ALTERATIONS
Feedroll Section Before and After Conversion
AUTOLEVELLING SENSOR
ARRANGEMENT
Webdoff Assembly Top View
AUTOLEVELLING SENSOR
ARRANGEMENT
Autolevelling Sensor arrangement near
Calendar Roller in Webdoff Assy
ELECTRICAL FUNCTIONAL
BLOCK DIAGRAM
HMI + PANEL
(HUMAN MACHINE INTERFACE)
AUTOLEVELLING SENSOR
DISPLACEMENT: 0 TO 10MM
OUTPUT: 0 TO 10VDC
DOUBLE LAP
CRUSHROLL LAPPING
LICKERIN SPEED LOW
SLIVER BREAKAGE
RS232/RS485
COMMUNICATION
PROTOCOL
PLC
(PROGRAMMABLE LOGIC
CONTROLLER)
DOFFER MOTOR AC DRIVE
3 PHASE VFD
FREQUENCY CMD: 0 TO 10VDC
RATING: 2.2KW
FEEDROLL MOTOR AC DRIVE
3 PHASE VFD
FREQUENCY CMD: 0 TO 10VDC
RATING: 0.75KW
CYLINDER MOTOR
BRUSH MOTOR
FAN MOTOR
WEBDOFF PNEUMATIC PISTON
AUTOLEVELLING SENSOR
TEST REPORT
12.000
10.000
8.000
6.000
4.000
2.000
Series1
0.000
1
0.9
0.8
0.7
0.6
0.5
-4.000
0.4
0.3
0.2
0.1
0
-0.1
-0.2
-0.3
-0.4
-0.5
-0.6
-0.7
-0.8
-0.9
-1
-2.000
DISPLACEMENT SAMPLE
2 MM
TOTAL DISPLACEMENT
10VDC
-6.000
-8.000
-10.000
-12.000
OUTPUT SAMPLE
2 VOLT
TOTAL OUTPUT
10VDC
Autolevelling Sensor Signal Conditioner
Sample Test Report
Programmable Logic
Controller (PLC)
Programmable Logic Controllers, or PLCs, operate according to userprogrammed internal logic. Unlike office computers, PLCs are
designed to be operated in industrial environments
for the control and operation of manufacturing process equipment
and machinery.
Programmable Logic
Controller(PLC)
•Input Unit
Monitors the change in status from an input device connected to the PLC
•Output Unit
It generates signals to be sent to an output device.
•CPU Unit
It governs all PLC activities. The primary function
is to examine the status of inputs, execute the
program, and update the outputs. The CPU unit
contains the memory section used to hold user
program and data.
•Programming Device
Enter and monitor user program.
•Power Supply
The power supply provides power to the CPU
and the bus connection between each unit.
Programmable Logic
Controller(PLC)
The Slim and Compact SX Series Supports Digital
Input/output and is built in with multiple analog I/O
Channels.
Specifications
 MPU Points: 10(4DI/2DO, 2AI/2AO)
Max I/O Points: 230
Program Capacity: 8000 Steps
Communication Port: Built-in RS-232
and RS-485, compatible with MODBUS
ASCII/RTU communication protocol
Built-in High Speed Counter
High-Speed Pulse Output @ 50KHZ
Variable Frequency
Drive(VFD)
A variable-frequency drive (VFD) 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.
Variable Frequency
Drive(VFD)
The Compact Design is ideal for small and medium
horsepower applications. The M Series Drive is
designed
to
provide
an
ultra-low-noise
operation, and includes several
innovative technologies that reduce
interference
Specifications
 Output Frequency: 0.1 to 400Hz
Adjustable V/F Curve and Vector Control
Auto Torque Boost & Slip Compensation
Built-in PID Feedback Control
Built-in MODBUS Communication, baud rate upto
38,400
MERITS OF OUR
SYSTEM
 Hank Variation% between -0.04 to +0.04
Expected 5m CV less than 2.5%
Expected Uster data U% between 3% to 4.5%
Expected Power Savings by 5 - 7%
Expected Production(KG) Increase by 10 - 15%
Electrical and Mechanical Maintenance cost can
be reduced by 10%