Industrial
automation SYSTEM for
Technology/Process Description:
Applied
Automation was started in the year 1991 with primary focus to provide quality process
automation systems for the textile spinning industry. Applied has established
itself since then as a solution provider to the industry using Multi vendor PC,
PLC, Process Control Hardware and Software
Applied specializes in software development in the areas of
- Visualization, Process Control and Communication involving PC and PLCs.
- Data acquisition software
- Supervisory Computers Monitoring and Control software
- Process monitoring and control
- Customized graphical user interface
- Real-Time and embedded systems
- Vision Based Real Time Applications
Technology/Product Specifications:
product 1: promise
Promise - Is an acronym for "Production
Management Information Systems Environment". Promise is a state-of-the
art, Dedicated Computer Controlled Production Monitoring System that is capable
of collecting and reporting upto-the-minute all of the necessary data to aid in
the efficient management of a weaving mill. The complete monitoring system can
be networked with remotely located terminal nodes. These terminals can be
located either within the plant, such as in manager's office, or at a remote
location up to one km away.
Functions of Promise
looms: The desired
objective of a successful weaving mill is to produce high quality fabric economically
and as free from faults as possible, this is achieved to a large extent by
monitoring through Promise system, which acts as a tool for the shop floor
technicians by providing accurate:
Loss of Utilization
(Out-of Production times)
Stoppages - up to 8
distinct stoppages with reasons including Weft, Warp.
Stoppage analysis.
Production report shift
wise/ sort wise for any period and upto the minute.
Instantaneous and average
Loom speeds.
Warp change schedule
Maintenance scheduling of
machines
Technical
Specifications
|
Suitability |
Can
be installed on Airjet, Rapier, Shuttle looms with Electronic or
Electro-mechanical stop motion. |
|
Data Capture Drives (DCD) |
Hardware
for Data Gathering from upto 128 Scanner Modules. |
|
Scanner Modules (SM) |
Installed
on Looms for collecting Data on production, stoppages, type of stoppage,
speed of Looms and time to attend the stoppage. One Scanner per Loom. Upto 8
stoppages can be distinctly recorded. |
|
Promise Server |
Computer
System to communicate with DCDs, Upto 4 DCDs can be connected to one Promise
Server. |
|
Remote Monitor |
|
|
Communications |
Serial
Distance: 100 meters between DCD and Promise Server 1000 meters between DCDs
and Scanner Modules. |
|
Connectivity Standard |
Standard:
Novell Compatible LAN, Windows NT Based Network Optional : UNIX based Mini
Computers, OS/2 Based Systems. |
|
Optional Features |
Interface to keyboard input
modules for Data entry from looms Directly to Promise Server and interface to
bar coad system.
|
Features of Promise Looms
Weaving Mills information
System of the future with user friendly menu based system.
All data - without loss
of any details is available for reports and Query on the terminals for over a
period of one year depending on the storage capacity of the computer.
Comprehensive reporting
system in table with freely selectable time periods.
Trend Analysis of Weavers
efficiency, loss of utilization due to different stoppages, repairs and
miscellaneous stoppages are available for query by the user.
User Benefits from Promise looms
Promise exercises the
best control on the loom shed. The computer system gives accurate information
from which an action plan can be formulated to maximize utilization and
production. This system can be connected to existing multi-user computer
network (Novell LAN or Windows based) and can provide the following information
from any of the terminals connected to it.
This
information is presented in a well layed out manner on any of the remotely
located terminals in the mills, Information regarding the operating behaviors
of the machines is analyzed in a decisive manner which helps to
Establish
tighter control of mill norms for Production and Productivity, with deviations
and exception areas easily detected for remedial action.
Establish
ideal operating conditions with regards to humidification, yarn material
quality, warp preparation and to ascertain optimum machine settings.
Determine
work loads and effectively optimize allocation of machines.
Controls
Utilization of machines by analyzing causes for loss of utilization and help
undertake suitable action.
Plan
maintenance of machines and schedule accordingly so as to reduce out of
production times.
Plan
and Control Production on a continuous basis and ensure target production is
achieved.
Take
instant decisions and monitor resultant actions.
Systematic
Warp and style planning can be achieved as all necessary information is
available with respect to Production, Warp Change, Efficiency and Loom
allocation.
product 2: fOREIGN FIBRE
CONTROL CHAMBER (ffcc)
Applied FFCC FS04 is a state-of-the-art system for removing
contaminants from cotton in the blow room line. FFCC FS04 employs the world's
best Machine Vision hardware & software technologies combined with high
speed pneumatics to detect and remove contaminants. FFCC FS04 is comfortably
installed on existing Blow room lines. Depending on the line and production
throughput flexible options exist to position the equipment in the line.
Installing FFCC FS04 ensures consistent quality of cotton with respect to
contamination. it is possible to reduce or even eliminate manual cleaning. End
customer gets yarn of higher quality with lesser contamination levels.
Features
Based on color CCD camera
Technology
Single & Dual chamber
models, with optimized design for handling one or two lines simultaneously
Field proven reliability
and performance
Key Components
The material Transport systems
Consists of a transport duct through which the cotton
passes. This duct has a transparent illuminated section (Detection Zone) for
the cameras to view and capture images of passing cotton tufts. Just below the
Detection Zone, an array og high speed pneumatic air nozzles are positioned to
fire out the contaminants. the ejection zone further has a sideways opening in
the duct directly opposite to the air nozzles. this enables separation and
collection of contaminants into a waste collector box. The material transport
subsystem has been designed so that no alteration to existing material
transport speeds are current production rates are maintained. By avoiding sharp
bends, cotton quality with respect to neps is left largely unaffected.
The Machine Vision
subsystem
Consists of the high speed high resolution Color CCD cameras
positioned on either side of the transport duct, and an industrial Computer
integrated with imaging hardware/software. The subsystem is further
complemented with high quality lighting and reflection mirrors to enhance the
cameras' view of passing cotton. The high
speed and sensitivity of the Color CCD cameras make it possible to detect very
accurately foreign material of minute dimensions. High
frequency long length fluorescent tube lights provide adequate and uniform
lighting under all conditions. The World's best Industrial Computer and imaging
hardware/software ensure highest levels of reliable operations.
Principle of Operation
The transport duct has a transparent illuminated section
(Detection Zone). Images of cotton passing through Images of cotton passing
through this section, are captured by two high speed Color CCD cameras located
on either side. Captured images are processed by an Industrial computer
equipped with imaging hardware, to detect foreign material as they pass by the
Ejection Zone. The ejected material are collected in a waste collector box and
transported out separately. Good material free of contaminants passes through
for further processing in the blowroom line.
The Software subsystem consists of the Operator Interface
and sophisticated algorithms that control the operation of the entire
equipment. The core image processing engine employs the most advanced
techniques to acquire images of detect and eject foreign material at the
highest sensitivity levels possible. It has capabilities to automatically
adjust to different cotton mixes, varying lighting conditions and provide
complete control of the system to the user unlike most other equipment. The
Operator Interface puts the user completely in control. The settings are easy
to understand, intuitive and offer great flexibility to control the equipment.
Operational statistics provided by the software let the users exactly
understand the performance and tune the equipment to get the best results. The
diagnostics tools provided as a part of the Operator Interface help
troubleshooting in the unlikely case of a problem.
|
Technical
Specifications |
||
|
|
FFCC Single Chamber |
FFCC Dual Chamber |
|
Enclosure |
Dust-Proof;
IP54 |
Dust-Proof;
IP54 |
|
Dimensions:
1600 x 1400 x 2300 mm |
Dimensions:
2300 x 1400 x 2500 mm |
|
|
Duct Size |
925
x 100 / 80 mm |
780
x 100 / 80 mm each duct |
|
Cameras |
CCD
Color |
CCD
Color |
|
256
RGB Color levels |
256
RGB Color levels |
|
|
Lighting |
High
frequency fluorescent long length 54 Watt tubelights |
High
frequency flourescent long length 54 Watt tubelights |
|
Ejection |
High
speed Pneumatic air nozzles |
High
speed Pneumatic air nozzles |
|
Compressed
air 6 kg/cm2 |
Compressed
air 6 kg/cm2 |
|
|
Control System |
Industrial
PC with high speed |
Industrial
PC with high speed |
|
image
acquisition |
Image
acquisition |
|
|
Operator Interface Panel |
Touch
screen Colour LCD Monitor |
Touch
screen Colour LCD Monitor |
|
Cooler |
Standard |
Standard |
|
Power |
415
VAC, 3 phase, 50/60 Hz, |
415
VAC, 3 phase, 50/60 Hz, |
|
2
Kw consumption |
2
Kw consumption |
|
|
Capacity |
Upto
1000 kg / hour |
Upto
500 kg / hour each line |
Company Profile
|
Company Name |
Applied Automation Systems Pvt. Ltd |
|
Address |
S.F. No. 415, Thaneer Pandal, Opp.
Geethanjali School, Peelamedu, Coimabtore-641004 |
|
Contact person |
Mr. Gopi Krishna |
|
Phone |
+91-422-5541633, 09842217933 |
|
Fax |
- |
|
E-mail |
|
|
Web Site |
|
|
Year of Establishment |
1990 |
|
Product(s) Manufactured |
Industrial Automation Products |
|
Production (FY-05) (Products
contributing most to the sales) |
FFCC (Foreign Fiber Control
Chamber) – 20 units ; PROMISE(Production Management Information Systems
Environment) -200 units |
|
Sales Turnover |
FY 05: USD 1.1
Mn FY 04: USD 0.9 Mn FY 03: USD 0.8 Mn
|
|
Foreign Collaboration |
Nil |
|
Manpower Total (Nos.) |
50 |
|
Raw Materials / Equipment used |
IPC, Image Acquisition Hardware,
Sheet metal Enclosures, PLC, Sensors and
Transducers, Computers |
|
Effluent Generated |
Non Polluting |
Broad Profile of Project
Offer
|
Project |
To Manufacture Industrial Automation System for Textile
Mills |
|
Capacity per Annum |
PROMISE(Production Management Information Systems
Environment): 250 FFCC(Foreign Fibre Control Chamber): 50 |
|
Land Requirements/ Building Requirements |
2500 Sq.M |
|
Plant & Machinery and Test
Equipment |
IPC, Image Acquisition Hardware, Sheet metal Enclosures, PLC, Sensors and Transducers,
Computers |
|
Electrical Installation |
20 HP |
|
Implementation Period |
6 Months |
|
Manpower Required |
25 |
|
Raw Materials / Equipment Required |
IPC, Image Acquisition Hardware, Sheet metal
Enclosures, PLC, Sensors and
Transducers, Computers |
|
Total Project Cost |
USD 0.33 Mn |
|
Expected Annual Sales |
USD 0.35 Mn |
|
Profitability |
10 % |
|
Form of Offer |
Turnkey Project |