System Architecture

Each textile machine is equipped with a Machine Terminal, which serves as the primary data acquisition unit. Key features include:

• Analog & Digital Input Interfaces:
  • These interfaces connect directly to sensors or to points on the machine control panel.
  • Capable of capturing a wide range of parameters such as:
    • Machine speed
    • Stop/start signals
    • Power consumption
    • Air consumption
    • Other operational or energy-related signals (e.g., temperature, humidity, vibration levels)
  • Real-Time Processing:
    • Raw signals are processed locally on the Machine Terminal.
    • Processed data includes metrics like production output, efficiency, and utility consumption.
  • User Interface:
    • LCD Display: Shows live machine parameters including speed, production, efficiency, etc.
    • Keyboard: Allows operators to input data and select relevant operational parameters.

• Machine Terminals are equipped with inbuilt wireless communication modules.
• Data is transmitted from each terminal to centrally located Access Points (APs).
• APs are connected via PoE (Power over Ethernet) switches to ensure both power and network connectivity.
• Network Redundancy: Backup communication paths are in place to ensure uninterrupted, real-time data flow to the central system.

This setup ensures uninterrupted, real-time data flow to the central system.

• A Central Computer runs the DATALOG Central Software, which acts as the heart of the system.
• Features of DATALOG Central Software:
  • Data Aggregation: Collects structured data from all Machine Terminals.
  • Database Storage: Stores data in a MySQL database, either locally or on the cloud, based on mill preference.
  • Data Security: Data is encrypted both in transit and at rest. Access to the database is controlled with strict user authentication and authorization protocols. Regular backups are performed to ensure data integrity.
  • Web-Based Interface:
    • Dashboards for real-time monitoring
    • Analytical reports in graphical and text formats
    • Master data management and assignment modules

• ERP Integration:
  • Supports interfacing with third-party ERP systems for seamless data synchronization.
  • Data can be transferred in real-time or at predefined intervals.
• Multi-Channel Data Access:
  • Data is accessible remotely via Static IP.
  • Real-time dashboards can be displayed on large LCD panels on the shop floor.
  • Alerts and Notifications: Alerts are triggered when machine downtime exceeds a set threshold, efficiency drops below a target, or other critical parameters deviate from normal ranges. Notifications are sent via SMS or WhatsApp.
  • Automated reports can be emailed to designated stakeholders.
  • Export options available in Excel and PDF formats.

• The system is designed with a scalable architecture, allowing for the addition of more Machine Terminals and Access Points as the mill expands. The Central Software and Database are capable of handling increased data volume over time.

• Regular system maintenance procedures include software updates, database optimization, and hardware checks. Technical support is available via phone and email to assist with troubleshooting and resolve any issues that may arise.

• Real-time operational visibility
• Improved machine efficiency and maintenance insights
• Streamlined decision-making through accurate data
• Scalable and ERP-compatible architecture
• Enhanced data accessibility across devices and locations