Spinning

ONLINE PRODUCTION & POWER MONITORING SYSTEM FOR SPINNING

RING FRAME | SPEED FRAME | COMBER | LAP FORMER | DRAW FRAME | CARDING

Datalog Online Monitoring System 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 mills continuously to improve productivity, save costs, translating into higher profits.

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

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). 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 Sructure

  • 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