The dying and knitting of yarn for textiles is a process that has existed for thousands of years. This process has long been machine automated, but with advanced SCADA software that provides an intuitive development environment for robust monitoring and data acquisition applications, it’s possible to follow that process through every step from raw material to finished product. Using a SCADA system that gathers data from multiple textile stenter machines, Ekoten Textile, located in Izmir, Turkey, is able to record and compile data from every stage of their textile production process. With this data, Ekoten Textile can compare everything from output by machine, to the quality of the finished product.
Ekoten Textile uses a machine known as a stenter machine in the production of their fabrics. These machines stretch or straighten fabric so that it can then be colored or marked according to specific patterns. Production and process data is critical when using these machines. In order to manage a consistent fabric quality, batch and recipe data must be recorded. Additionally, all costs must be considered, particularly in an industry as price sensitive as the textile industry. Having a SCADA system that is capable of both recording process data and recipe and batch information is critical for any textile company that wishes to remain competitive.
Ekoten realized that they would need a robust SCADA system capable of recording this information, so they searched for a system integrator capable of creating an application that would meet their requirements. Eventually, Ekoten Textile chose Enmos, a system integration company in Turkey that specializes in the textile industry. Enmos, a certified system integrator with InduSoft, was familiar with InduSoft Web Studio, and was certain that it would meet the requirements set forth by Ekoten.
Figure 2: The alarm pop-ups clearly display alarm status, and allow for quick identification of problem areas. In these screens, temperature and analog values are monitored.
Enmos realized that in order to capture and store the data gathered from the machines, a vital part of the application would rest in the ability of the SCADA application to connect to an SQL database. Not only machine data, but batch information would need to reside in and be easily recalled from a database. InduSoft Web Studio has a patented method for communicating with SQL databases, making InduSoft Web Studio the ideal development platform for this application. Traceability was also a consideration. It was important for Ekoten that machine operators have individual login and password credentials in order to track each batch to the operator who handled it. Because InduSoft Web Studio offers support for user and group based identification, it was easy to incorporate these necessary features.
Figure 3: The temperature offset page allows operators to calibrate zone temperatures.
The project that Enmos created for Ekoten gathers data from ten different textile stenter machines. InduSoft Web Studio connects directly to these machines through industrial PCs, the Simplex 640 IPC of Enmos that is certified by Indusoft, with Delta Electronics brand DVP14SS211R PLCs using the Modbus protocol. The processes are started and stopped separately for every batch on these machines. Indusoft Web Studio is connected to the SQL server on the main server that houses the process set data, and sends the active values to the server.
The machine speed, top, bottom and exit feeding speed, circulation fan speeds, zone temperatures, circulation fan alarms, machine active, burner active contacts, fabric sensor, electrical and natural gas consumption relays are all monitored, as well as other needed analog and digital signals that are connected to the PLC side.
The batch number is checked through the SQL database, and the process data and set values are sent from the SQL database to the screen. If the batch number doesn’t exist in the SQL database, then the process will not be started. If the batch number does exist in the database, then the program is started. After startup, the process values are recorded, and the active values will be checked according to the tolerances of the set values. If the active values are outside these acceptable parameters, then the alarms for these values will be recorded and shown with pop-up pages.
The electrical and natural gas consumptions are all recorded for each process and 8 hour shifts. The stop conditions of the process are also entered from the pop-up page for further information on the production. The operators log in with their password in every 8 hour shift and user activity is also logged by this system.
The flow of data is diverse, which allows Ekoten to take advantage of a detailed view of their operations on a shift-by-shift basis. This allows operators to monitor the costs of each batch closely, and find the ideal combination of efficiency in time and materials, and quality. The result of this is an end product that is cost effective and well made.
As a certified system integrator that specializes in the textile industry, Enmos now has a benchmark application to show to other potential clients who may have similar requirements. Because InduSoft Web Studio is such a flexible SCADA application development platform, it will be easy to adapt these techniques to new and unique textile SCADA applications.
||Figure 4: The job order number check page allows operators to verify each batch against the records in the SQL database.
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