ONLINE PRODUCTION & POWER MONITORING SYSTEM FOR SPINNING
RING FRAME | SPEED FRAME | COMBER | LAP FORMER | DRAW FRAME | CARDING
Datalog Online Monitoring System for Spinning facilitates continuous monitoring of Production and Power at each machine individually and collectively. The data is processed to generate reports that help in seamless running of all operations and identify weak areas, help textile mills continuously to improve productivity, save costs, translating into higher profits.
Spinning Mills have the choice of selection between Production Monitoring & Production cum Power Monitoring.
Production Monitoring
- Ring Frame & Speed Frame - Kg, RPM, M/min, TPI, Doffs, Stops
- Preparatory - Prod Kg, Stops and Min /stop
- Allmachines connected to one computer
- ERP Interface / Excel Transfer
Machine Level
- Optimise and strike balance - Cost vs Production —UKg
- Optimise speed profiles, machine parameters
- Prevent avoidable breakdown
- Monitor Health of the Motor to Improve its performance
- Identify problems in Mechanical alignment of the drive shafts, bearings , lubrication
Department Level
- By comparing the various motors / machines running similar counts and rating, helps in bringing the lower performing machines at par with the best.
Production & Power Monitoring
Datalog Monitors Power parameters like KWh, KVA, Power Factor, Frequency, Voltage and Current for each Ring Frame and motor temperature (Optional) along with production data like Kg, Hanks, TPI, Doff Time, Efficiency. The integrated information helps to optimise productivity, minimise cost and maximise profits.
Mill Level
- Monitor utilities—compressors , H- Plant
- Monitor MV, SSB, DB etc
- Account and reconcile for total units consumed, identify leaking points and weak areas.
- Help optimise quality of power - Power factor, Hz, voltage
- Forewarn deteriorating points before it is too late .
- Optimise maintenance practice and schedules.
- Accurate and actual data for costing
Central computer and user Nodes
- Various reports on Production, Stoppage, Efficiency
- Doff Wise & Doff Prediction Reports for Speed Frame & Ring Frame
- Comparison reports
- Performance reports for Top Level Management
- Snap study, Exception reports, Operator Planning
- Easy identification of Efficiency of the machines in different colours
- Efficiency Trend Graph
Machine Terminal
- Display of key data
- Provision to enter Long Stop reason (Long Stop Code)
Options
- Score board, SMS Alerts Module, Email reports, Doff status display
Details of Parameters Monitored in Spinning Machines
| Particulars | Carding | Unilap, Hilap Sliverlap, Ribbonlap | Comber | Drawing Breaker / Finisher | Roving / Simplex | Ring Frame | |||
|---|---|---|---|---|---|---|---|---|---|
|
Machine Terminal with Keybord & Display |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
Sensor for Speed / Delivery Rate Measurement in Meters per Minute (M/Mi) / RPM |
Delivery Coil /
Drum |
Delivery Coil /
Drum |
Delivery Coil /
Drum |
Delivery Roller |
Delivery Roller |
Delivery Roller |
|||
|
Sensor for Twist Measurement (TPI / TPM) |
NA |
NA |
NA |
NA |
Yes |
Tin Roller |
|||
|
Signal / Sensor for Doff / Can Change Measurement |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
Machine Run Time Monitoring |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
Production in Kgs / Meters / Yards calculation based on M/Mi & Run Time |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
Calculate & Display of Grams per Spindle Shift (GPSS) |
NA |
NA |
NA |
NA |
Yes |
Yes |
|||
|
Calculate & Display of TPI / TPM |
NA |
NA |
NA |
NA |
Yes |
Yes |
|||
|
Signals from Machine that can be connected to Machine Terminal |
Can Change
Sliver Break
Back Side Jam |
Empty Coil
Back Side Creel Break
Doff
Lap Jam |
Doff Change
Can Change
Sliver Break
Table Trumpet Jam
Lap Jam |
Doff
Can Change
Sliver Break
Creel Break
Auto level stop |
Doff
Sliver Break
Creel Break |
Doff |
|||
|
Long Stop Reason Entry on Machine Terminal. |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
Stop Start & End time is automatically sensed by Machine Terminal |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
Display of Production on Machine Terminal |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
Display of Delivery Rate / Speed on Machine Terminal |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
Display of Efficiency on Machine Terminal |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
Display of Stop Details on Machine Terminal |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
Optional: |
|||||||||
|
Power Monitoring by Installing Datalog Power Monitor with Current Transformer |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
Display of Following Parameters on Machine Terminal and Central Computer |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
Voltage – Phase to Phase |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
Voltage – Phase to Neutral |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
Current – Each Phase |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
Power Factor |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
Frequency |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
KVA |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
KW |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
KWh |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
KVAR |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
Units Consumed per KG of production |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
Power Cost Report |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
|
Kvarh |
Yes |
Yes |
Yes |
Yes |
Yes |
Yes |
|||
Wiring Diagram of Datalog Power Monitor on Ring Frame
Hardware and Software configuration
A Machine Terminal is installed on each machine to monitor Production and Power data (optional) in spinning mills. Machine Terminals are connected through the Multiplexer to the Central Computer that generates various reports. Connection from the Machine Terminals to the central computer can be wired or wireless.
Datalog at the heart of productivity
When it comes to providing total solutions for textile automation, Datalog is in a league on its own. Incorporating innovative technologies, Datalog has quietly established its reputation as a trusted partner in progress for customers cross the Globe. Strong focus on R&D and clear perception of customer requirements have contributed to the company’s ability to provide customised solutions to help improve productivity and quality. Datalog’s facilities are top-of-the-line. A dedicated team of engineers backed by highly experienced technical people at the helm ensures that every product from their stable delivers results.
Report Structure
- Text & Graphical Reports
- MachineWise, ArticleWise, OperatorWise, Supervisor Wise, Department Wise
- Production Reports, Stoppage Reports,Doff Report, Doff Prediction Report, Efficiency Reports
- Power consumption,Power factor,Units consumed, KVA,etc.,reports related to power
- Power consumed vs Production comparison for each DOFF, Shiftetc.,
- Air Consumption Reports(Optional)
Models & Optional Attachments
