AUTOMATION AND CONTROL MECHANISM FOR TEXTILE DYEING PROCESS USING PLC AND IOT

Abstract

The present invention relates to an automated control system for the textile dyeing process, using Programmable Logic Controllers (PLC) and Internet of Things (loT) technology to enhance efficiency, reduce operational costs, and improve accuracy in dyeing operations. The invention automates key aspects of the dyeing process, including controlling dye bath I

Specification

Technical Field
The present invention relates to the field of industrial automation and textile
engineering. Specifically, it focuses on automation and control mechanisms for the
textile dyeing process, utilizing Programmable Logic Controllers (PLC) and Internet
of Things (loT) technologies to enhance the efficiency, accuracy, and real-time
monitoring of the dyeing process. This invention also leverages the use of remote
access and monitoring to streamline plant operations and optimize resource
management.
Field of the Invention
The invention pertains to automated control systems in the textile industry,
particularly those that manage the complex operations of dyeing fabric in winch
dyeing machines and boilers. The system automates the entire dyeing process by
integrating sensors, actuators, and communication interfaces through a centralized
PLC unit, while employing loT for remote monitoring and control. The primary aim
is to reduce labor dependency, operational costs, and human error, while improving
the overall precision and quality of textile dyeing operations.
Background of the Invention
The traditional textile dyeing process involves several stages that require
constant manual intervention to ensure uniform dye application, temperature control,
and management of dye bath levels. These processes are not only labor-intensive but
are also prone to inaccuracies due to human errors, leading to inconsistent fabric
quality and inefficient use of resources.
In manual operations, skilled labor is essential to monitor various parameters,
such as dye bath levels and temperatures, which are crucial for ensuring proper dye
bonding to fabrics. Additionally, the requirement for continuous oversight during
low-order or no-order periods increases operational costs without contributing to
plant profitability.
With the advent of Industry 4.0 and advanced automation technologies, it is
now possible to automate these tedious processes using PLC and loT to maintain
precision and optimize performance. Automation enables continuous monitoring and
control, improving process reliability, minimizing ope~ational costs, and providing
higher product quality.
The invention described here seeks to overcome the inefficiencies of manual
textile dyeing processes by automating the control of critical variables such as dye
bath levels and temperatures using sensors and PLCs. Furthermore, the
incorporation of loT technology allows for real-time monitoring and remote access,
thereby significantly enhancing the operational management of dyeing plants.
Summary of the Invention
This invention introduces an automated control system for the textile dyeing
process, utilizing a PLC and loT-enabled monitoring system. The system controls
key aspects of the dyeing process, including dye bath levels and temperature, and
enables real-time adjustments via solenoid valves and steam-controlled boilers.
The PLC functions as the central processing unit, receiving input from level
and temperature sensors installed in the winch dyeing machine. The data is then
processed to control solenoid valves that regulate the flow of water, dye, and steam
into the machine. The system automatically adjusts the conditions based on preset
values for optimal dye application.
An loT module is incorporated to enable cloud-based remote monitoring of
the entire dyeing process. Real-time data from the sensors is uploaded to the cloud,
providing plant operators with the ability to monitor the process remotely, ensuring
they can make informed decisions even from distant locations.
Key features of the invention include:
}> Automated control of dye bath levels using level sensors and solenoid valves.
}> Continuous monitoring and regulation of dye bath temperature through realtime
feedback from temperature sensors.
}> Cloud integration for remote monitoring and access, enabling real-time
process supervision and emergency interventions from any location.
}> A reduction in labor costs and elimination of manual errors, particularly
during low or no production periods.
}> Enhanced efficiency and accuracy in dye bonding and fabric processing.
Detailed Description of the Invention
System Architecture
The textile dyeing system comprises the following components:
}> Winch Dyeing Machine: Responsible for holding the fabric and rotating it
through the dye bath to ensure even application of dyes.
}> Boiler: Supplies steam to regulate the temperature of the dye bath, crucial for
optimal dye bonding.
}> Sensors:
o Level Sensor: Monitors the dye bath level and ensures the fabric is
fully submerged during the dyeing process .
o Temperature Sensor: Continuously measures the temperature of the dye
bath to maintain the optimal range for dye bonding.
}> PLC (Programmable Logic Controller): Acts as the control hub, processing
inputs from the sensors and actuating control mechanisms such as solenoid
valves and boilers.
}> Solenoid Valves: Control the flow of water, dye, and steam into the winch
dyeing machine, based on instructions from the PLC.
~ loT Module: Transmits real-time data to the cloud, enabling remote
monitoring and control of the dyeing process.
Process Flow
~ The PLC receives continuous input from the level and temperature sensors
installed in the winch dyeing machine.
~ Based on preset parameters, the PLC actuates solenoid valves to regulate the
flow of water, dye, and steam. When the dye bath level falls below the desired
threshold, the solenoid valve opens to allow the entry of additional dye or
water.
~ If the temperature falls below the optimal range, the PLC activates the boiler,
allowing steam to enter the dye bath to maintain the required temperature.
~ The loT module sends real-time data from the PLC to a cloud server, where it
can be accessed by authorized personnel for monitoring purposes. This
enables plant operators to intervene remotely if necessary, ensuring process
continuity and minimizing the risk of errors.
CLAIMS
Claim 1: An automated textile dyeing system, comprising:
~ A winch dyeing machine,
~ A boiler,
~ Solenoid valves,
~ Level sensors and temperature sensors,
~ A Programmable Logic Controller (PLC),
~ An Internet of Things (loT) module, wherein the PLC monitors and controls
the dye bath level and temperature, and the loT module transmits real-time
data for remote monitoring and control.
Claim 2: A method for controlling a textile dyeing process, comprising:
~ Monitoring the dye bath level and temperature using level and temperature
sensors,
~ Automatically actuating solenoid valves to regulate the flow of dye, water,
and steam,
~ Adjusting boiler operations to maintain the desired temperature,
~ Transmitting real-time process data to a cloud serve.r for remote access· and
monitoring.
Claim 3: A remote monitoring system for a textile dyeing process, wherein:
~ The loT module integrates with the PLC to provide continuous data
transmission to a cloud server, allowing operators to monitor and control the
dyeing process from distant locations.

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