Smar

tDat
aMoni
tor
ingSy
stem f
orPowerLoom Usi
ngI
OT

Ai
swary aB,Anant hiK,Dav i
dNi kilKumarSA
B.E.
[El
ectr
ical
andEl ectroni
csEngi neeri
ng],PSGI nst
it
uteofTechnol
ogy
andAppl i
edr esearch,Neelambur -641062.
Emai
li
d:[email protected]
n, 21e108@psgi tech.ac.i
n,21e112@psgit
ech.
ac.
in

TheAbst ract-Text i
lei ndust ryhasoccupi edt hesecond vari
ous y arn processes such as sheddi ng,pi cking,
positionnextt oagr icul ture.Duet othei ncr easei n battening and taki
ng-up oper at
ions.Rai sing ofwar p
popul ati
ongr owt h,thet exti
lei ndustryhasbeen yarnst of orm al oopt hroughwhi cht hef i
lli
ngy arn,
i
ncr easingal oti nt oday '
swor ld.Powerl oom i soneof carriedbyt heshuttl
eisinsertedi sknownassheddi ng.
thekeydev elopment si nt hei ndust r
iali
zat i
onof Asi nglecrossingoft heshut tlef r
om onesi deoft he
weav ing.Itprov idesempl oymentt oov er35mi lli
onin l
oom t otheot herisknownaspi ckingoper ation.The
thecount ry.Theuseofmanpoweri nt hei ndust rycan l
ay i
ngdownoft heyarnfil
lisknownasbat tening.Wi t
h
ber educedwi tht hehel pofaut omat i
on.Themai ngoal eachwav i
ngoper at
ion,t
henewl yconstructedf abricwi l
l
ofindust r
yi stoachi ev emaxi mum ef f
iciencywi thhigh bewoundonacl ot
hbeam andi tiscal
ledast akingup
product i
vity
.Thi scanbeachi evedwi t
hthehel pofthis oper at
ion.The mai n adv antages ofaut omat ion are
system.Thi spaperpr ovidesaut omat i
ont opowerl oom i
ncr eased t hr
oughput,i ncreased qual i
ty,i mpr oved
byusi ngont oi sol ator s,optical sensor s,pr oximi t
y robustnessandr educti
onofhumanl oss.
sensorandcur rentt r ansf or
mer s.Thedat awi l
l be
uploadedi nt hewebser verforv i
ewingi tany ti
meand
anywher e.Raspber ryPi isusedasacont rollerinthis
I
I. Li
ter
atur
eSur
vey
paper .Thissy stem mai nlyai mst ocol l
ectv ari
ousdat a
suchast heamountofcl othwov en,l
abourdet ail
s,weft
andwar pdef ects. Thedensi tyoft hemat eri
alpr oducedi sdet erminedby
usingawebcamer aandami cr o-comput ert hatal l
ows
KeyWor ds:Powerl
oom,wef
tandwar
p,r
aspber
rypi
, todet ermi net hegeomet ri
cdi mensi onoft hei ntervals
sensor
s. betweent hebasi cy arnsoft hef abricbyVl adimir.Thi s
i
sanappl i
cat i
onoft hev isi
onsy stem i nt heweav ing
I
. I
ntr
oduct
ion l
oom i ndust ry,especi all
yf orf abricdef ect sdet ection.
Dey iDongi ntroducedasy stem wi thhi ghr eliabil
i
tyand
Textil
e i ndustry has become t he second l ar gest easy mai ntainabi l
it
y by use ofdualbus and dual
empl oy mentgener atingsect orint hewor ld.Loom dat a regionalpr ocessorand ant i-
jammi ng t echni ques f or
i
nterpr etation sy stem i s an Aut omat ed I nformat ion hardwar e and sof tware r eliabi
lity㈤.Thi s sy stem
System whi ch gi ves bet t
ercont r olov erpr oduct ion i
ncludes moni t
orl ayer,regi onalpr ocessorand t he
moni toringandt akescor r
ecti
v est epsi mmedi ately.It managementl ay er.IndustrialEt herneti sal sousedi n
provides bet t
ercont rolov erqual ityand pr oduct i
on. thi
ssy stem.Av ersatilecont rollersy stem i sdev eloped
Cont i
nuousper formanceofev erysi nglel oom i nami ll byKi m whi ch isessent ialf oraut omat i
on oft extil
e
givesahi ghpr oduct ivity.Withitsincr easinggr owt hand machi ner y.Thi s paperdet ermi nes t he sensor s and
demand,t he t ext i
lei ndustryf aces many pr obl ems actuator s and an el ectroni c ci rcui
t r
y f or t he
whichhav etobechanged.Oneoft hemet hodst osol ve communi cationbet weent hemachi nesal ongwi tht he
thosepr oblemsi st heuseofaut omat i
oni nthet extil
e cont r
oller.Thewef tandwar pdef ectsar efound
i
ndust ries.Aut omat ioncanbedef i
nedast hepr ocess
of r educi ng human assi stance i n t he pr ocess
performed.I nmostsect orsoft ext i
lemanuf actur i
ng, I
II
. Rel
atedWor
k
automat i
on i s one of t he maj or key st o qual it
y Progr ammabl e Logi c Cont roll
er( PLC)i s used as a
i
mpr ov ementandcostcompet itiveness.Pr ocessest hat cont rolleri n a pl ain weav ing machi ne.Mostoft he
hav ebeenaut omat edr equi
rel esshumani ntervent ion moni tor ingandcont r
oll
ingappl i
cationsar edonewi th
andl esshumant iert odev elop.Apr ocesscont rolor the hel p ofPLC i ni ndust ri
es.The pl ainl oom i s
automat i
onsy stem i susedt oaut omat i
cal lycont rolan cont rolled mechani call
y and i tdoes nothav e any
i
ndust ry.The Pr ocess Aut omat i
on Sy stem uses a electroni csy stem f orcont r oll
ingpur poses.Becauseof
networ kt oi nterconnectsensor s,cont roll
er s,oper ator manyadv ant agessuchasr obust ness,I/Oi nterf
ace,
terminal sandact uat ors. simpl icityPLCi schosenf orcont roll
ingpur poses.The
wef tandwar pdef ect sint hissy stem aref oundwi t
ht he
Thet exti
l
eindust rymainlydeal
swi ththedesignand help ofpr oximityand I R sensor s.Accor ding tot he
producti
onofy arn,cl
oth,andthei
rdistr
ibut
ions.Power i
nf ormat ion obt ained by t he PLC cont roll
er,t he
l
oom i soneoft hemachi neusedfortexti
leproduct
ion i
nduct ionmot orismadeonorof fwitht hehel pof
i
n most smal l-
scalei ndust
ri
es.Power l oom i sa cont act orsorr elays.I fther eisanyf aultinthesy stem,
mot or
ized l
oom power ed bya l i
ne shaft
.Themai n the machi ne can be t urned of fwi tht he help of
component s oft he l
oom ar e warp beam,heddles, cont act ororr el
ay.Al lthepr ocessi ngj obi sdoneby
harnesses,shuttle,reed and takeuprol
l.There are Progr ammabl e Logi c Cont rol
ler. Thi s sy stem
i
nt r
oduces quali
ty assurance.Labourwor k can be the pr esence of met al obj ects wi thout any
reduced but i t needs separ ate labours for all physicalcont actwi ththeobject s.Thedur abi
li
tyof
measurement act iv
iti
es. Thi s syst
em has many the swi tch can be enhanced and ensur es
drawbacks.Someoft hedrawbacksar e:thesystem i
s mai ntenance f ree wor k. Osci l
lator circuit
quitecost
lyandt heamountofcl ot
hwov encannotbe gener atesahi ghf requencyalter nati
ngf i
eldatthe
measured automat i
call
y.The sensed dat a can be activeface.Theosci ll
ati
onget sst oppedwhenany
viewedonlyatthewor ki
ngar eaanditcannotbev i
ewed met alobj ectisbr oughtintot hef i
eld.Hencet he
anytimeandany where. demodul ated v oltage f eedi ng t he t ri
gger
disappear s.I
tisusedt ofindt hef aultinthemet al
i
.e.war pmet alduet othef orcebeatoft hewar p
I
V. Pr
oposedSy
stem beam.The pr oximi tysensori s shown i nfig.2.
Thepr oposedsy st em usesembeddedsy stem as Someoft hefeaturesofpr oximit ysensorare:
akeycomponent .I tconsi stsofv arioussensor s
such as opt icalsensor ,pr oximitysensor ,reed Nomi
nal
vol
tage:
10-
30VDC
sensorand cur rentt r
ansf ormer .The pr oximi t
y
sensori susedt of i
ndanymet alcont actatt he Vol
tagedr
op:
0.8-
7V
war p.Theopt icalsensori susedt of i
ndt hedef ect
i
nt heweav ingt hreadorpi ck.Reedsensori sused Loadcur
rent
:300mA
tocal culatet heamountofcl othwov en.Cur rent
tr
ansf ormerused her ei st of ind t he cur rent Nol
oadcur
rent
:10-
20mA
consumedbyt hepowerl oom.Al lt hesenseddat a
willbet r
ansf erredt othecont roll
er .Raspber ryPi i
s Swi
tchi
ngf
requency
:200Hz
used as a cont rollerint he pr oposed sy st
em.
Cont roll
erpr ocessest henecessar ypr ocessand Sensi
ngdi
stanceTol
erance:
10%
displayst hedat ai n LCD and wi llbeupl oaded
cont i
nuousl yt ot heweb ser ver.I ft herei sany
defectorf aul tint heweav ingt hread,t hemachi ne
canbeaut omat ical l
yst opped.Thebl ockdi agram
ofthepr oposedsy stem isshowni nf i
g.1.

Fi
g.3:
ReedSensor
B. ReedSensor(
Opt
oisol
ator
)

MOC7811I ROpt oisolatedSlotSensori

susedt o
measuret heamountofcl othwoven.MOC7811i s
a slott
ed opt o isolator module,wi t
h an I R
tr
ansmitterandaphot odiodemount edoni t
.It
consist
sofapl asti
cbodyi nwhichIR LED and
photodi
ode mount ed f acing each other are
encl
osed.Whenl ightemi ttedbyIRLEDisblocked
becauseofal ter
natingsl otsoftheencoderdisc
Fi
g1:
BlockDi
agr
am l
ogiclevelofthe

photodi
odechanges.Thechangecanbesensed
V. Har
dwar
eUsed byt hemicrocont
rol
lerorbydiscret
ehar dware.It
consist
soff ourpinssuchascol l
ect
or,emi tt
er,
A. Pr
oxi
mit
ySensor cathodeandananode.Cat hodeandanodewi llbe
presentatonesi deandcol l
ect
orandemi t
terin
opposit
eside.Thecoll
ectoremit
tervol
tageis5V.

Fi
g.2:
Proxi
mit
ySensor

I
nduct
ivepr
oxi
mit
ysensor
sar
eusedt
oident
if
y
 withCPUr angi
ngf rom 700MHzt o1.2GHz.I thas
anonboar dmemor yr angi
ngf r
om 256MBt o1
GBRAM.Theoper ati
ngsy stem ofRaspberryPiis
storedint heSDcar dandsev eralUSBpor t
sar e
availabl
ef orbothaudi oandv i
deoout put
.Ithasa
buil
t-in Wi -
Fimodul e. Lower l ev
elout put is
providedbyanumberofGPI Opinswhi chsupport
2
common pr otocol
sl i
ke I C. Py t
hon is used
BCM283764bi tARMvQuad
Fi
g.4:
Curr
entTransfor
mer Fi
g.5.RaspberryPi 3
C. Curr
entTransfor
mer

Cur rentt ransformers are used t o measur e or

moni t
ort hecur r
entint heleadofanacpower
circuit.A cur renttransformeri s defined as an
i
nst rumentt ransformeri n which the secondar y
cur r
enti spr oporti
onaltot hepr i
mar ycurrentand
differsi n phase f r
om i tbyan angl e whi ch is
appr oximat el
yzer oforanappr opr i
atedirecti
onof
the connect ions. Typical value of secondar y
cur r
enti s1 A or5 A.I treduceshi gh volt
age
cur r
entt o a much l owerv alueand pr ovi
desa
conv enientwayofsaf el
ymoni tori
ng theact ual
elect r
icalcur r
entf l
owingi nanAC t r
ansmi ssion
l
ineusi ng ast andard ammet er.5 Amp cur rent
transfor merisshowni nfi
g.4. CorePr ocessor,Bluet
oot h Low Energy(
BLE)on
board,
40pi nextendedGPI O, CSIcameraportand
DSIdi splay portf or connecti
ng displ
ay with
RaspberryPi.

PowerSuppl
y

Raspber ryPiispower edbya+5. 1Vmi croUSB

supply .Thecurrentr equi
redbyt heRaspber ryPi
dependsont heappl i
cati
onbei ngused.Themodel
Busesbet ween700- 1000mAdependi ngont he
connect edperi
pher al
s.Themaxi mum powerused
Fig.5:Opti
cal
Sensor i
s1Amp.I ftheUSBdev i
ceisused,Piusesmor e
D. Opt
icalSensor than
1Amp.GPI Opinsdr aw50mAdi st
ri
butedacr oss
allpins,anindividualGPI Opincandr aw only16
mA.
The ot herhardwar e’s are power ed externall
y
usinga12Vr egulatedpowersuppl y.Theci rcui
t
diagram of12VRegul at
edpowersuppl yisshown
i
nf ig.7.Itconsistsofa230/ 12V,1Ast epdown
transformer.The12VACi sgi vent ot hebr i
dge
recti
fiercir
cuitandt hent ov olt
ager egulatorLM
7812.

VI
. Sof
twar
eUsed

A. Raspbi
an
Theopt i
calsensorusedher eisalsoknownas
throughbeam sensor s.Thissy stem consistsof Raspberry Piwor ks on t he specialoper at
ing
twosepar atecomponent s:thetransmitt
erandt he system knownasRaspbi an.I tisaf reeoper at
ing
receiver
.Theyar eplacedopposi t
etoeachot her
. system based on Debi an,opt imized f or the
Thet r
ansmitterprojectsal ightbeam ont ot he RaspberryPihardware.Raspbiancomeswi thover
receiver
.An i nt
err
uption oft he li
ghtbeam i s 35,000packages:precompi ledsof t
war ebundl ed
i
nter r
uptedasaswi t
chsi gnalbythereceiver.The i
n a nice f or
matf oreasy i nst
all
at i
on on t he
opticalsensorisshowni nfig.5. RaspberryPi.Theoperati
ngsy st
em isl oadedina
microSDcar d.

E. Raspberr
yPi3
Themicr
ocontr
oll
erusedintheproposedsy
stem B. Node.
js
i
sRaspberr
yPi3modelBwhi chisshowninf i
g.
6.
Iti
saser i
esofsmal lsi
ngleboardcomputers Nodej
s i
s an open sour
ce, cr
oss pl
atf
orm
Jav aScript runt
ime env i
ronment for execut ing
Jav aScriptcodeSer verside.Node.j
sisanev ent
drivenar chit
ecturecapableofasy nchr
onousI /O.
Init
iall
yJav aScriptwaspr imari
lyusedf orclient-
side scr i
pti
ng, in whi ch scr i
pts written i n
Jav aScriptareembeddedi na webpage' sHTML.
Itenabl esJav aScri
pttobeusedasser versi de
scripti
ng and r uns scri
ptst o pr
oduce dy nami c
webpages.
Fi
g10.
Har
dwar
e
C. Py
thon
The har dware connect i
ons of the proposed
Pythonisaneasyt olearnpower f
ulpr ogrammi ng system i
sshowni nfi
g.11.Theproxi
mitysensor
,
l
anguage.Raspber r
yPimost l
yr unson Py thon reed sensorand cur rentsensorareinter
faced
programs. I t suppor ts Object -
Or i
ent ed withthemi crocontrol
l
erthatisRaspber
ryPi.The
programmi ng and st ruct
ured programmi ng and sensedv al
ueswi llbedispl
ayedintheLCDandi n
many of i t
s f eatures suppor ts f unct i
onal webpageusi ngIOT.
programmi ngandaspect -
ori
entedpr ogr ammi ng.
I
tr educedt hecostoft heprogram mai ntenance. I
X. Concl
usi
on
ThePy thoni nter
preterandtheext ensi
v est andar d
l
ibrary are av ai
labl
ei n source orbi naryf or m In t his paper , we pr oposed a met hod f or
withoutchargef orallmajorplatf
or ms,andcanbe moni toring t he power l oom funct i
ons
fr
eelydistr
ibuted. automat i
callywi tht hehel pofRaspber r
yPiasa
cont r
oller.Raspber r
yPii soneoft headv anced
VI
I. Exper
iment
alResul
ts cont r
ollersused now- a-day s.I nt his paper ,the
senseddat af rom t heloom wi llbedi splayedt o
A. Si
mul
ati
onResul
ts theuseri nLCDaswel lasi nt hewebser ver.Ithas
sever aladv antages such as t he data can be
Theproposedsystem worksonRaspber
ryPi
.The viewed any time and any wher e,t he amountof
si
mulati
on of t he pr oposed syst
em i s clothwov encanbecal culat ed,t hemachi necan
i
mplementedusingPI C 16F877A.Thesoft
ware best oppedi ft het hreadi nt hewef tandwar p
usedforsimulat
ionoutputsarePROTEUS8and breaks.I thasadi sadv antaget hati tcannotbe
MPLABV8. 33 cont r
olledwi thoutmanpower .Ahumani sneeded
tochanget hewef torwar pt hreadwhi chi sf ound
cut.I n f uture, manual assi stance i n beam
replacementandwar pbr eakscanbeaut omat ed
andmul tiloomscanbecont roll
edbyuseofa
singlecont r
oller.

X. Ref
erences

[
1] Alexandr uA. M.
,DeMaur oA.
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Sisca F. G.
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i L.,
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manuf acturi
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g.8showsthel
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ocessi
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ectint
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il
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[
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