Ventura Automation Services Inc

bendembarrassΗλεκτρονική - Συσκευές

2 Νοε 2013 (πριν από 4 χρόνια και 10 μέρες)

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Ventura Automation Services Inc


Loop Length/Production DAQ System


Server


RS
-
485 to RS
-
232 Converters


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

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

UTL

87.45%

PROD

2145 KGS

EFF

97.35%

YARN

HIGH

UTL

87.45%

PROD

2145 KGS

EFF

97.35%

YARN

HIGH

SJ145

UTL

87.45%

PROD

2145 KGS

EFF

97.35%

YARN

HIGH

SJ145

UTL

87.45%

PROD

2145 KGS

EFF

97.35%

YARN

HIGH

SJ145

UTL

87.45%

PROD

2145 KGS

EFF

97.35%

YARN

HIGH

SJ145

UTL

87.45%

PROD

2145 KGS

EFF

97.35%

YARN

HIGH

SJ145

UTL

87.45%

PROD

2145 KGS

EFF

97.35%

YARN

HIGH

SJ145

UTL

87.45%

PROD

2145 KGS

EFF

97.35%

YARN

HIGH

SJ145

UTL

87.45%

PROD

2145 KGS

EFF

97.35%

YARN

HIGH

SJ145

UTL

87.45%

PROD

2145 KGS

EFF

97.35%

YARN

HIGH

SJ145

UTL

87.45%

PROD

2145 KGS

EFF

97.35%

YARN

HIGH

SJ145

UTL

87.45%

PROD

2145 KGS

EFF

97.35%

YARN

HIGH

SJ145

UTL

87.45%

PROD

2145 KGS

EFF

97.35%

YARN

HIGH

SJ145

UTL

87.45%

PROD

2145 KGS

EFF

97.35%

YARN

HIGH

SJ145

UTL

87.45%

PROD

2145 KGS

EFF

97.35%

YARN

HIGH

SJ145

UTL

87.45%

PROD

2145 KGS

EFF

97.35%

YARN

HIGH

SJ145

UTL

87.45%

PROD

2145 KGS

EFF

97.35%

YARN

HIGH

SJ145

UTL

87.45%

PROD

2145 KGS

EFF

97.35%

YARN

HIGH

SJ145

UTL

87.45%

PROD

2145 KGS

EFF

97.35%

YARN

HIGH

SJ145

UTL

87.45%

PROD

2145 KGS

EFF

97.35%

YARN

HIGH

SJ145

Shed
No/M
C

Eff

%

Total

Prod

1/23

87.45

21225

2/17

89.00

12567

3/10

97.87

5665

4

84.43

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

UTL

87.45%

PROD

2145
KGS

EFF

97.35%


# MC:6

KUMARAV
EL

UTL

87.45%

PROD

2145
KGS

EFF

97.35%


# MC:6

DINESH

UTL

87.45%

PROD

2145
KGS

EFF

97.35%


# MC:6

MANIVAN
NA

UTL

87.45%

PROD

2145
KGS

EFF

97.35%


# MC:6

SENTHIL

UTL

87.45%

PROD

2145
KGS

EFF

97.35%


# MC:6

KUMARAV
EL

UTL

87.45%

PROD

2145
KGS

EFF

97.35%


# MC:6

DINESH

UTL

87.45%

PROD

2145
KGS

EFF

97.35%


# MC:6

MANIVAN
NA

UTL

87.45%

PROD

2145
KGS

EFF

97.35%


# MC:6

SENTHIL

UTL

87.45%

PROD

2145
KGS

EFF

97.35%


# MC:6

KUMARAV
EL

UTL

87.45%

PROD

2145
KGS

EFF

97.35%


# MC:6

DINESH

UTL

87.45%

PROD

2145
KGS

EFF

97.35%


# MC:6

MANIVAN
NA

UTL

87.45%

PROD

2145
KGS

EFF

97.35%


# MC:6

SENTHIL

UTL

87.45%

PROD

2145
KGS

EFF

97.35%


# MC:6

KUMARAV
EL

UTL

87.45%

PROD

2145
KGS

EFF

97.35%


# MC:6

DINESH

UTL

87.45%

PROD

2145
KGS

EFF

97.35%


# MC:6

MANIVAN
NA

UTL

87.45%

PROD

2145
KGS

EFF

97.35%


# MC:6

SENTHIL

UTL

87.45%

PROD

2145
KGS

EFF

97.35%


# MC:6

KUMARAV
EL

UTL

87.45%

PROD

2145
KGS

EFF

97.35%


# MC:6

DINESH

UTL

87.45%

PROD

2145
KGS

EFF

97.35%


# MC:6

MANIVAN
NA

UTL

87.45%

PROD

2145
KGS

EFF

97.35%


# MC:6

SENTHIL

Shed /

Kniter

Eff

%

Total

Prod

1/
Kumarvel

87.45

1225

1/
Sundar

89.00

2567

3

97.87

5665

4

84.43

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

PLAN

10200

PROD

7845
KGS

QUALIT
Y

97.35%


# MC:6

Ab
-
1549

ALL
KNITTERS

PLAN

10200

PROD

7845
KGS

QUALIT
Y

97.35%


# MC:6

Ab
-
1549

PLAN

10200

PROD

7845
KGS

QUALIT
Y

97.35%


# MC:6

Ab
-
1549

PLAN

10200

PROD

7845
KGS

QUALIT
Y

97.35%


# MC:6

Ab
-
1549

PLAN

10200

PROD

7845
KGS

QUALIT
Y

97.35%


# MC:6

Ab
-
1549

PLAN

10200

PROD

7845
KGS

QUALIT
Y

97.35%


# MC:6

Ab
-
1549

PLAN

10200

PROD

7845
KGS

QUALIT
Y

97.35%


# MC:6

Ab
-
1549

PLAN

10200

PROD

7845
KGS

QUALIT
Y

97.35%


# MC:6

Ab
-
1549

PLAN

10200

PROD

7845
KGS

QUALIT
Y

97.35%


# MC:6

Ab
-
1549

PLAN

10200

PROD

7845
KGS

QUALIT
Y

97.35%


# MC:6

Ab
-
1549

PLAN

10200

PROD

7845
KGS

QUALIT
Y

97.35%


# MC:6

Ab
-
1549

PLAN

10200

PROD

7845
KGS

QUALIT
Y

97.35%


# MC:6

Ab
-
1549

PLAN

10200

PROD

7845
KGS

QUALIT
Y

97.35%


# MC:6

Ab
-
1549

PLAN

10200

PROD

7845
KGS

QUALIT
Y

97.35%


# MC:6

Ab
-
1549

PLAN

10200

PROD

7845
KGS

QUALIT
Y

97.35%


# MC:6

Ab
-
1549

PLAN

10200

PROD

7845
KGS

QUALIT
Y

97.35%


# MC:6

Ab
-
1549

PLAN

10200

PROD

7845
KGS

QUALIT
Y

97.35%


# MC:6

Ab
-
1549

PLAN

10200

PROD

7845
KGS

QUALIT
Y

97.35%


# MC:6

Ab
-
1549

PLAN

10200

PROD

7845
KGS

QUALIT
Y

97.35%


# MC:6

Ab
-
1549

PLAN

10200

PROD

7845
KGS

QUALIT
Y

97.35%


# MC:6

Ab
-
1549

STYLE

Style/Work

Order#

Plan

Actual

1234/500

2456

1225

2323/345

3445

2567

REAL TIME PRODUCTION MONITORING SYSTEM
-

DASHBOARD

ALL MACHINES

STYLE

PLANT
INFO

PRODUCTI
ON
REPORTS

ALL KNITTERS

REAL TIME PRODUCTION MONITORING SYSTEM
-

DASHBOARD

ALL
MACHINES

STYLE

PLANT
INFO

QUALITY

ALL
KNITTERS

REPORTS


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