INSTITUTE OF INDUSTRIAL

ELECTRONICS ENGINEERING, (PCSIR)

KARACHI

Complex Engineering Problem:

Automation of Long Hemming Sewing Machine
at Afroze Textile

IE473: Industrial Process Control

Fourth Year Fall Semester

Submitted By
Bilal Abbassi (20025)

Submitted To
Engr. Agha Muhammad Shakir
Table of Content
1) Executive
Summary…………………………………………………………………………………………………
……………….…1
2) Problem
statement…………………………………………………………………………………………………
………….………1
3) Working mechanism of long hemming
machine………………………………………………………………………..1
4) Maintenance
cost………………………………………………………………………………………………………
…………….. 1
a) Routine
maintenance…………………………………………………………………………………………
…………..…..1
b) Emergency
repair………………………………………………………………………………………………
……...………..1
c) Downtime
cost…………………………………………………………………………………………………
…………….……1
5) After
upgradation………………………………………………………………………………………………
………………..…... 2
6) Possible
solutions…………………………………………………………………………………………………
………………..... 2
a) Robotic Sewing
Systems……………………………………………………………………………………………
……..….2
b) Automated Material
Handling……………………………………………………………………………………..………
2
c) Integrated PLC
Control………………………………………………………………………………………………
..………2
7) Proposed Solution
……………………………………………………………………………………………………….
……..…….3
(1) Integrated PLC and HMI
Control……………………………………………………………….……..…….3
(a) Why do we use Delta DVP-80EH?
……………………………………………………………………3
 (b) Compatibility with Digital
I/Os………………………………………………………………….………3
(c) Modbus Communication
Support……………………………………………………………….……3
(d) Reliability and
Performance…………………………………………………………………………….
.3
(e) Cost-
Effectiveness…………………………………………………………………………
…………..…….3
(f) Why do we use Wecon PI3070ig-C? ……………………………………………..
…………………4
(g) Compatibility and
Integration…………………………………………………………………………..4
(h) Advanced Visualization and
Control……………………………………………………….…………4
(i) IoT Connectivity for Cloud Data
Access………………………………………………..……………4
(j) Data Analysis and
Optimization…………………………………………………………………………4
8) Design and
Integration………………………………………………………………………………………………
………………..5
9) Cost Analysis and Economic
Viability……………………………………………………………………………………..……5
10) Compliance and
Standards………………………………………………………………………………………………
……..…..5
11) Practical
Implementation…………………………………………………………………………………………
……………..…..5
12) Programming for
PLC………………………………………………………………………………………………………
…………..6
13) Programming for
HMI……………………………………………………………………………………………………
……..……..7
14) Conclusion………………………………………………………………………………………………
…………………………………..7
15) Recommendations………………………………………………………………………………………
………………….…………..7
Executive Summary:
This report presents a comprehensive proposal for the automation of the long hemming sewing and
edge cutting machine in the Afroze Textile Industry. The current manual and relay logic operation of the
machine results in frequent maintenance and decreased production efficiency. By implementing a PLC-
based control system integrated with IoT and HMI technologies, we aim to address these challenges and
improve overall operational efficiency.

Problem Statement:
The Afroze Textile Industry faces challenges with the existing manual and relay logic operation of its long
hemming sewing and edge cutting machine. These challenges include high maintenance costs, frequent
downtime, and limited production efficiency.

Working mechanism of long hemming machine:

The operation of the long hemming sewing and edge cutting machine involves manual processes and
limited automation. Towels were manually filled into the U box (towel filling) located at the back side of
the machine. Once filled, operators use a pedal to transfer the towels from the U box to the take-up
roller. The motor of the take-up roller was controlled by a relay system.

As the towels moved towards the header for cutting, edge detection was performed to determine the
length of the towel. However, this process relied heavily on manual intervention and lacked efficiency. In
case of thread breakage during sewing, no alarm was triggered, leading to potential defects in the final
product.

Maintenance cost:
The maintenance costs which are machine requires are given below,

Routine Maintenance: The routine maintenance tasks such as lubrication, cleaning, adjustments, and
minor repairs. This may include the cost of labor and replacement parts.

Emergency Repairs: The expenses incurred due to unexpected breakdowns or malfunctions. Include
the cost of emergency service calls, replacement parts, and overtime labor if applicable.

Downtime Costs: The impact of machine downtime on production schedules, missed deadlines, and
potential loss of revenue. The cost of idle labor, delayed orders, and any penalties incurred due to late
deliveries.

Considering the current manual operation, the estimated annual maintenance cost is 3 to 3.5 lac in PKR.

After Upgradation:
Following the upgradation of long hemming sewing and edge cutting machine, significant improvements
have been made in automation and efficiency. The introduction of PLC and HMI technology, along with
the integration of photoelectric sensors, has revolutionized the operational workflow.

Now, the photoelectric sensor installed near the U box indicates the level of towels present, defining
maximum, medium, and minimum limits. This automated monitoring ensures optimal utilization of
space within the U box, preventing overfilling or shortages.

Manual operation via the pedal has been replaced by PLC-controlled signals, streamlining the process of
transferring towels from the U box to the take-up roller. The motor of the take-up roller is now
seamlessly integrated with the PLC system, enabling precise control and synchronization of towel
feeding.

Furthermore, edge detection for cutting the towel at the header has been enhanced, ensuring accurate
and consistent sizing. In case of thread breakage during sewing, the yarn sensor now triggers an alarm,
stops the machine, alerting operators to take immediate action. This proactive approach minimizes
defects and ensures the quality of the final product.
Overall, the upgradation of the long hemming sewing machine has optimized production efficiency,
reduced manual intervention, and enhanced product quality, positioning the Afroze Textile Industry for
increased competitiveness in the textile manufacturing market.

Possible Solutions:
Our aim to fully automate its long hemming sewing machine operations, several solutions can be
considered to achieve comprehensive automation:

Robotic Sewing Systems:

Introduce robotic sewing systems equipped with advanced stitching algorithms and vision-guided
technology.

Robotic arms can precisely manipulate fabric panels and perform intricate sewing tasks with high speed
and accuracy.

Automated Material Handling:

Implement automated material handling systems, such as conveyor belts, robotic grippers, and pick-and-
place mechanisms.

These systems can transport fabric panels between workstations, facilitate seamless material loading
and unloading, and optimize workflow efficiency.

Integrated PLC Control:

Utilize Programmable Logic Controllers (PLCs) to orchestrate the operation of robotic sewing systems,
material handling equipment, and auxiliary devices.

Integrate PLC-based control logic to synchronize machine movements, coordinate sewing patterns, and
ensure smooth production flow.

Proposed Solution:
Integrated PLC and HMI Control:
PLC System: We propose the purchase of Delta PLC (Model DVP-80EH) system, renowned for its
reliability, scalability, and compatibility with industrial applications. The estimated cost for the PLC
system is 60,000 PKR.

Why do we use Delta DVP-80EH?

Choosing the Delta PLC (Model DVP-80EH) for the automation of the machine, particularly considering
the digital I/Os and Modbus communication, can be justified based on several factors:

Compatibility with Digital I/Os:

The Delta PLC (Model DVP-80EH) is designed to accommodate digital I/Os, which aligns with the
requirements of the long hemming sewing machine's automation process.
Digital I/Os are commonly used in industrial automation applications due to their reliability and ease of
integration.

Modbus Communication Support:

Modbus communication is widely adopted in industrial automation for its simplicity and effectiveness in
facilitating communication between devices.

By supporting Modbus communication, Delta PLC can easily interface with other devices, such as
sensors, actuators, and HMIs, within the automation system.

Reliability and Performance:

Delta is a reputable manufacturer known for producing high-quality PLCs with robust performance and
reliability.

The DVP-80EH model offers advanced features and capabilities suitable for industrial environments,
ensuring stable and efficient operation of the automation system.

Cost-Effectiveness:

The Delta PLC (Model DVP-80EH) offers a competitive price point compared to other PLC brands with
similar capabilities.

Its affordability makes it an attractive option for businesses seeking cost-effective automation solutions
without compromising performance or reliability.

HMI: For the Human-Machine Interface (HMI), we recommend Wecon HMI (Model PI3070ig-C), offering
an intuitive user interface design and seamless integration with the PLC system. The estimated cost for
the HMI is 45,000 PKR.

Why do we use Wecon PI3070ig-C?

Integrating the Wecon HMI (Model PI3070ig-C) with the Delta DVP-80EH PLC and incorporating IoT
capabilities for cloud data access offers several advantages in the context of automating the long
hemming sewing machine:

Compatibility and Integration:

The Wecon HMI and Delta DVP-80EH PLC are designed to work seamlessly together, ensuring
compatibility and ease of integration.

This compatibility simplifies the setup process and allows for efficient communication between the HMI
and PLC, facilitating data exchange and control commands.

Advanced Visualization and Control:

The Wecon HMI provides advanced visualization capabilities, allowing operators to monitor and control
the long-hemming sewing machine with ease.

Its user-friendly interface enables intuitive operation and real-time feedback, enhancing productivity and
reducing the risk of errors.
IoT Connectivity for Cloud Data Access:

Incorporating IoT capabilities into the HMI enables seamless connectivity to cloud-based platforms,
facilitating remote monitoring and data access.

By accessing data on the cloud, operators and management can monitor machine performance, track
production metrics, and analyze trends from anywhere with an internet connection.

This remote accessibility enhances decision-making processes, enables proactive maintenance, and
improves overall operational efficiency.

Data Analysis and Optimization:

Cloud-based data storage and analytics enable advanced data analysis techniques, such as machine
learning and predictive maintenance algorithms.

By analyzing historical data and identifying patterns, operators can optimize machine settings, improve
production workflows, and minimize downtime.

Insights gained from cloud data analysis empower organizations to make data-driven decisions and
continuously improve performance.
Design
and Integration:
Develop a robust control logic using ladder logic programming to regulate machine speed, stitch
accuracy, and material handling.

Integrate IoT devices for remote monitoring and predictive maintenance, facilitating real-time machine
performance monitoring.

Implement an intuitive HMI interface for operators to monitor machine status and troubleshoot issues
efficiently.

Cost Analysis and Economic Viability:

The total estimated cost for purchasing the PLC system and HMI is 105,000 PKR.

Conducting a comprehensive cost-benefit analysis reveals potential cost savings through reduced
maintenance requirements, decreased downtime, and increased production efficiency.

The expected return on investment (ROI) is projected to be achieved within 4 to 5 months based on
anticipated cost savings and increased productivity.
Compliance and Standards:
Ensure compliance with industry standards and safety regulations, adhering to relevant codes for
machine safety and operation.

Practical Implementation:
Conduct field visits to the Afroze Textile Industry to assess the operational environment and gather
specific requirements.

Develop and test a prototype of the PLC-based automation system, ensuring functionality, reliability, and
compatibility with existing components.

Provide comprehensive training and documentation for operators and maintenance personnel.

Programming for PLC:

Here's a simplified ladder logic programming for controlling the long-hemming sewing machine
Programming for HMI:
Here's a simplified HMI programming for controlling the long-hemming sewing machine.
Conclusion:
The proposed automation solution offers the Afroze Textile Industry the opportunity to modernise its
long-hemming sewing machine, addressing maintenance issues, enhancing production efficiency, and
achieving long-term cost savings. By embracing PLC-based control integrated with IoT and HMI
technologies, the Afroze Textile Industry can remain competitive in the evolving textile manufacturing
landscape.

Recommendations:
Proceed with the implementation of the proposed automation solution after thorough evaluation and
stakeholder approval.

Ensure adequate training and support for operators and maintenance personnel during the transition
phase.

Continuously monitor and evaluate the performance of the PLC-based control system, implementing
optimizations as necessary.

This proposal represents a strategic step towards modernizing operations and achieving sustainable
growth in the Afroze Textile Industry.