International Journal of Pure and Applied Mathematics

Volume 119 No. 10 2018, 937-947

ISSN: 1311-8080 (printed version); ISSN: 1314-3395 (on-line version)
url: http://www.ijpam.eu
Special Issue
ijpam.eu

Smart Data Monitoring System for Power

Loom Using IOT
1
M. Saravanan, 2M. Jagadesh, 3V. Deepan, 4R. Divya, 5S. Gowri Manohari
and 6S.Gowrishankar
1,2,3,4,5,6
Department of ECE,
SNS College of Technology, Coimbatore,
Tamil Nadu, India.

Abstract
Textile industry has occupied the second position next to agriculture.
Due to the increase in population growth, textile industry has been
increasing a lot in today’s world. Power loom is one of the key
developments in the industrialization of weaving. It provides employment
to over 35 million in the country. The use of man power in the industry can
be reduced with the help of automation. The main goal of industry is to
achieve maximum efficiency with high productivity. This can be achieved
with the help of this system. This paper provides automation to power
loom by using onto isolators, optical sensors, proximity sensor and current
transformers. The data will be uploaded in the web server for viewing it
anytime and anywhere. Raspberry Pi is used as a controller in this paper.
This system mainly aims to collect various data such as the amount of cloth
woven, labour details, weft and warp defects.
Key Words:Power loom, weft and warp, raspberry pi, sensors.

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1. Introduction
Textile industry has become the second largest employment generating sector in
the world. Loom data interpretation system is an Automated Information System
which gives better control over production monitoring and takes corrective steps
immediately. It provides better control over quality and production. Continuous
performance of every single loom in a mill gives a high productivity. With its
increasing growth and demand, textile industry faces many problems which has
to be changed. One of the method to solve those problems is the use of
automation in the textile industries. Automation can be defined as the process of
reducing human assistance in the process performed. In most sectors of textile
manufacturing, automation is one of the major key to quality improvement and
cost competitiveness. Processes that have been automated requires less human
intervention and less human tier to develop. A process control or automation
system is used to automatically control a industry. The Process Automation
System uses a network to interconnect sensors, controllers, operator terminals
and actuators.

The textile industry mainly deals with the design and production of yarn, cloth,
and their distributions. Power loom is one of the machine used for textile
production in most small-scale industries. Power loom is a motorized loom
powered by a line shaft. The main components of the loom are warp beam,
heddles, harnesses, shuttle, reed and takeuproll. There are various yarn
processes such as shedding, picking, battening and taking-up operations. Raising
of warp yarns to form a loop through which the filling yarn, carried by the
shuttle is inserted is known as shedding. A single crossing of shuttle from one
side of the loom to the other is known as picking operation. The laying down of
the yarn fill is known as battening. With each waving operation, the newly
constructed fabric will be wound on a cloth beam and it is called as taking up
operation. The main advantages of automation are increased throughput,
increased quality, improved robustness and reduction of human loss.

2. Literature Survey
The density of the material produced is determined by using a web camera and a
micro-computer that allows to determine the geometric dimension of the
intervals between the basic yarns of the fabric by Vladimir[6]. This is an
application of the vision system in weaving loom industry, especially for fabric
defects detection. Deyi Dong introduced a system with high reliability and easy
maintainability by use of dual bus and dual regional processor and anti-jamming
techniques for hardware and software reliability[3]. This system includes monitor
layer, regional processor and the management layer. Industrial Ethernet is also
used in this system. A versatile controller system is developed by Kim which is
essential for automation of textile machinery. This paper determines the sensors
and actuators and an electronic circuitry for the communication between the
machines along with the controller[11]. The weft and warp defects are found

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using sensors and the sensed data are displayed in the LCD as well as sent to the
user as a message using GSM[14].

3. Related Work
Programmable Logic Controller (PLC) is used as a controller in plain weaving
machine. Most of the monitoring and controlling applications are done with the
help of PLC in industries. The plain loom is controlled mechanically and it does
not have any electronic system for controlling purpose. Because of many
advantages such as robustness, I/O interface, simplicity PLC is chosen for
controlling purpose. The weft and warp defects in this system are found with the
help of proximity and IR sensors. According to the information obtained by the
PLC controller, the induction motor is made on or off with the help of
contactors or relays. If there is any fault in the system, the machine can be
turned off with the help of contactor or relay. All the processing job is done by
Programmable Logic Controller. This system introduces quality assurance.
Labour work can be reduced but it needs separate labours for all measurement
activities. This system has many drawbacks. Some of the drawbacks are: the
system is quite costly and the amount of cloth woven cannot be measured
automatically. The sensed data can be viewed only at the working area and it
cannot be viewed anytime and anywhere.

4. Proposed System
The proposed system uses embedded system as a key component. It consists of
various sensors such as optical sensor, proximity sensor, reed sensor and current
transformer. The proximity sensor is used to find any metal contact at the warp.
The optical sensor is used to find the defect in the weaving thread or pick. Reed
sensor is used to calculate the amount of cloth woven. Current transformer used
here is to find the current consumed by the power loom. All the sensed data will
be transferred to the controller. Raspberry Pi is used as a controller in the
proposed system. Controller processes the necessary process and displays the
data in LCD and will be uploaded continuously to the web server. If there is any
defect or fault in the weaving thread, the machine can be automatically stopped.
The block diagram of the proposed system is shown in fig.1.
POWER SUPPLY WEB PAGE PC LCD

RASPBERRY PI 3

OPTICAL SENSOR PROXIMITY REED SENSOR CURRENT

SENSOR TRANSFORMER

POWER LOOM

Fig. 1: Block Diagram of Proposed System

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5. Hardware Used
Proximity Sensor

Fig. 2: Proximity Sensor

Inductive proximity sensors are used to identify the presence of metal objects
without any physical contact with the objects. The durability of the switch can
be enhanced and ensures maintenance free work. Oscillator circuit generates
high frequency alternating field at the active face. The oscillation gets stopped
when any metal object is brought into the field. Hence the demodulated voltage
feeding the trigger disappears. It is used to find the fault in the metal i.e. warp
metal due to the force beat of warp beam. The proximity sensor is shown in
fig.2. Some of the features of proximity sensor are:
Nominal voltage: 10-30 VDC
Voltage drop: 0.8-7 V
Load current: 300 mA
No load current: 10-20 mA
Switching frequency: 200 Hz
Sensing distance Tolerance: 10%
Reed Sensor (Opto isolator)

Fig. 3: Reed Sensor

MOC 7811 IR Opto isolated Slot Sensor is used to measure the amount of cloth
woven. MOC 7811 is a slotted opto isolator module, with an IR transmitter and
a photodiode mounted on it. It consists of a plastic body in which IR LED and
photodiode are mounted facing each other are enclosed. When light emitted by
IR LED is blocked because of alternating slots of the encoder disc logic level of
the photodiode changes. The change can be sensed by the microcontroller or by
discrete hardware. It consists of four pins such as collector, emitter, cathode and
an anode. Cathode and anode will be present at one side and collector and
emitter in opposite side. The collector emitter voltage is 5 V. The reed sensor is
shown in fig. 3.

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Current Transformer

Fig. 4: Current Transformer

Current transformers are used to measure or monitor the current in the lead of an
ac power circuit. A current transformer is defined as an instrument transformer
in which the secondary current is proportional to the primary current and differs
in phase from it by an angle which is approximately zero for an appropriate
direction of the connections. Typical value of secondary current is 1 A or 5 A. It
reduces high voltage current to a much lower value and provide a convenient
way of safely monitoring the actual electrical current flowing in an AC
transmission line using a standard ammeter. 5 Amp current transformer is shown
in fig. 4.
Optical Sensor

Fig. 5: Optical Sensor

The optical sensor used here is also known as through beam sensors. This
system consists of two separate components the transmitter and the receiver.
They are placed opposite to each other. The transmitter projects a light beam
onto the receiver. An interruption of the light beam is interrupted as a switch
signal by the receiver. The optical sensor is shown in fig. 5.
Raspberry Pi 3

Fig. 6: Raspberry Pi 3

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The microcontroller used in the proposed system is Raspberry Pi 3 model B

which is shown in fig. 6.It is a series of small single board computer with CPU
ranging from 700 MHz to 1.2 GHz. It has an on board memory ranging from
256 MB to 1 GB RAM. The operating system of Raspberry Pi is stored in the
SD card and several USB ports are available for both audio and video output. It
has built in Wi-Fi module. Lower level output is provided by a number of GPIO
pins which support common protocols like I2C. Python is used as a
programmable language. It has Broadcom BCM2837 64 bit ARMv Quad Core
Processor, Bluetooth Low Energy(BLE) on board ,40 pin extended GPIO, CSI
camera port and DSI display port for connecting display with Raspberry Pi.
Power Supply

Raspberry Pi is powered by a +5.1 V micro USB supply. The current required

by the Raspberry Pi depends on the application being used. The model B uses
between 700-1000 mA depending on the connected peripherals. The maximum
power used is 1 Amp. If the USB device is used, Pi uses more than 1 Amp.
GPIO pins draw 50 mA distributed across all pins, an individual GPIO pin can
draw only 16 mA.

Fig. 7: 12V Regulated Power Supply

The other hardware’s are powered externally using a 12 V regulated power

supply. The circuit diagram of 12 V Regulated power supply is shown in fig. 7.
It consists of 230 /12 V, 1A step down transformer. The 12 V AC is given to the
bridge rectifier circuit and then to voltage regulator LM 7812.

6. Software Used
Raspbian

Raspberry Pi works on the special operating system known as Raspbian. It is a

free operating system based on Debian, optimized for the Raspberry Pi
hardware. Raspbian comes with over 35,000 packages: precompiled software
bundled in a nice format for easy installation on the Raspberry Pi. The operating
system is loaded in micro SD card.
Node.js

Node.js is an open source, cross platform JavaScript run time environment for
executing JavaScript code Server side. Node.js is an event driven architecture
capable of asynchronous I/O. Initially JavaScript are was primarily used for
client-side scripting, in which scripts written in JavaScript are embedded in a

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web page’s HTML. It enables JavaScript to be used as server side scripting and
runs scripts to produce dynamic web page.
Python

Python is an easy to learn powerful programming language. Raspberry Pi mostly

runs on Python programs. It supports Object-Oriented programming and
structured programming and many of its features supports functional
programming and aspect-oriented programming. It reduced the cost of the
program maintenance. The Python interpreter and the extensive standard library
are available in source or binary form without charge for all major platforms,
and can be freely distributed.

7. Experimental Results
Simulation Results

The proposed system works on Raspberry Pi. The simulation of the proposed
system is implemented using PIC 16F877A. The software used for simulation
outputs are PROTEUS 8 and MPLAB V8.33.

Fig. 8: No Defect

The fig . 8 shows the loom processing without any defect in the weft and warp.

Fig. 9: Warp Defect

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Figure. 9 shows the defect in the warp thread. In the simulation the defect is
shown such that when a warp thread is cut, the LCD shows the status warp
detected and machine stop.

Fig. 10: Weft Defect

Figure 10 shows the defect in the weft thread. In the simulation the defect is
shown such that when weft thread is cut, the LCD shows the status as weft
detected and machine stop.
Hardware Results

Fig. 11: Hardware

The hardware connections of the proposed system is shown in fig.11. The

proximity sensor, reed sensor and current sensor are interfaced with the
microcontroller that is Raspberry Pi. The sensed values will be displayed in the
LCD and in webpage using IOT.

8. Conclusion and Future Work

In this paper, we proposed a method for monitoring the power loom functions
automatically with the help of Raspberry Pi as a controller. Raspberry Pi is one
of the advanced controllers used now-a-days. In this paper, the sensed data from
the loom will be displayed to the user in LCD as well as in the web server. It has
several advantages such as the data can be viewed anytime and anywhere, the

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amount of cloth woven can be calculated, the machine can be stopped if the
thread in the weft and warp breaks. It has a disadvantage that it cannot be
controlled without man power. A human is needed to change the weft or warp
thread which is found cut. In future, manual assistance in beam replacement and
warp breaks can be automated and multi looms can be controlled by use of
single controller.

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