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  • Automation in a Textile Dyeing Factory

    Automation in a Textile Dyeing Factory

    Labor cost has been continually rising over the past two decades and employees have become more aware about employment standards legislation. As a result, many manufacturers have moved their operations to China or other countries where costs are lower and employee welfare regulations are less strict.


     

    Communications Modules  

    ADAM-4500 PC-based Communication Controller

    ADAM-4510

    General RS-422/485 Repeater

    ADAM-4510S Isolated RS-422/485 Repeater

    ADAM-4520 Isolated RS-232 to RS-422/485 Converter

    ADAM-4521 Addressable RS-422/485 to RS-232 Converter

    ADAM-4522 RS-232 to RS-422/485 Converter

    ADAM-4541 Multi-mode Fiber-Optic to RS-232/422/485 converter with mounting bracket

    ADAM-4561 1-port Isolated USB to RS-232/ 422/485 Converter

    ADAM-4572 Ethernet to Modbus Data Gateway

    ADAM-4581 1-port GSM to RS-232/422/485 Data Gateway

    ADAM-4570L 2-port Ethernet to RS-232 Data Gateway

    ADAM-4570S 2-port Ethernet RS-422/485 Data Gateway w/Security

     

    Remote Analog Output Modules  
    ADAM-4021 Analog Output Module

     

    Remote Analog Input Modules  
    ADAM-4011 Analog Input Module
    ADAM-4011D T/C Input Module with LED Display
    ADAM-4012 Analog Input Module
    ADAM-4013 Analog RTD Input Module
    ADAM-4016 Strain Gauge Input Module
    ADAM-4017 8-channel Analog Input Module
    ADAM-4018 8-channel Thermocouple Input Module
    ADAM-4018M 8-channel Analog Input Data Logger
    ADAM-4015 6-Channel RTD Module
    ADAM-4019 8-Channel Universal Analog Input Module
    ADAM-4017+ 8-channel Analog Input Module
    ADAM-4018+ 8-channel Thermocouple Input Module with Modbus

     

    Remote Digital I/O Modules  
    ADAM-4050 Digital I/O Module
    ADAM-4052 Isolated Digital Input Module
    ADAM-4053 16-channel Digital Input Module
    IA-3302 RS-232 Controlled Relays, PC Enabled Module
    ADAM-4024 4-Channel Analog Output Module
    ADAM-4051 16-channel Iso. DigitalInput w/LED Module
    ADAM-4055 16-channel Isolated Digital I/O w/LED Module

    Remote Relay Output Modules  
    ADAM-4060 Relay Output Module
    IA-3302 RS-232 Controlled Relays, PC Enabled Module

      

    Remote Counter Frequency Modules  
    ADAM-4080 Counter/Frequency Module
    ADAM-4080D Counter/Frequency Module with LED Display



    Introduction

    Labor cost has been continually rising over the past two decades and employees have become more aware about employment standards legislation. As a result, many manufacturers have moved their operations to China or other countries where costs are lower and employee welfare regulations are less strict. One textile dyeing manufacturer in northern Taiwan decided to keep his plant on the island, but he realized that he would have to improve his plant's competitiveness by reducing costs. The owner wished to employ a computerized automation system in his plant.


    System requirements

    The textile dyeing plant is of average size and contains 8 dyeing lines. Each line has 10 dyeing tubes. One of the main factors that affects dyeing quality is the strict control of temperature in each tube within the process. The owner used to hire field workers to record temperatures manually. An automatic system must be able to collect data remotely at a certain level of accuracy within a large space. The goal is to minimize the labor cost while maintaining product quality. The system must work reliably in a hot and noisy environment. Since margins are very slim in the textile dyeing industry, the owner was very concerned about cost.


    System architecture

    The ADAM-4013 RTD analog input module and a PT-100 thermal sensor was used in the front end of each dyeing tube. Each node in the production line is then connected to an RS-485 network. ADAM-4520 isolated RS-232 to RS-485 converters then convert the RS-485 signals to RS-232 signals for input to the host PC. The system diagram is shown above.

    ADAM-4013 RTD modules are available in either Pt or Ni types for measuring wide temperature ranges. It offers 2,3, or 4 wire connection. A highly precise current source supplies RTD excitation. The measurement resolution is up to 0.01°C. This enables reliable control of the tube's temperature.

    Eighty nodes are connected to the RS-485 network. The RS-485 network has good immunity to noise interference and can communicate over long distances, allowing it to serve in a large factory. Each tube's temperature is collected by an ADAM-4013 module and is transferred back to the control room in real time. On-duty supervisors can analyze data and make adjustments to the process.


    Conclusion

    The dyeing plant owner has reduced his field staff by 20% since the introduction of the automated system. Dyeing quality has improved. His plant is competitive with those in much cheaper labor markets and the number of employee complaints about harsh working conditions has been reduced.

     

     

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