MINISTRY OF EDUCATION AND TRAININGHO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION GRADUATION THESIS MAJOR: MECHATRONICS ENGINEERING TECHNOLOGY INSTRUCTOR: DUONG THE PHONG Ho Chi
OVERVIEW
Introduction to yarn winding machine
A yarn winding machine efficiently transforms large supply rolls of yarn, typically measuring 20-35 cm in diameter, into smaller, more manageable rolls ranging from 8-15 cm This process enhances usability and simplifies trading in the textile industry.
Figure 1-1 The supply yarn roll
Figure 1-2 The small yarn roll
There are two types of yarn winding machines: automatic and semi-automatic
- Semi-automatic yarn winding machine has 2 functions: winding and spread yarn on the plastic core
- Automatic yarn winding machines are more modern than semi automatic machines It have more functions like feeding cores and collecting finished yarn rolls
As a result, the working efficiency of automatic thread changing machines is higher than that of semi-automatic machines
Figure 1-3 Semi-automatic yarn winding machine
Figure 1-4 Automatic yarn winding machine
Problem statement
Many factories and businesses are interested in purchasing automatic yarn winding machines; however, high investment costs pose a significant barrier Currently, a substantial number of semi-automatic yarn winding machines are in operation.
Understanding this need, I came up with the idea of upgrading the semi-automatic machine buy adding the same functions as the automatic thread changer
Reusing the old machine body, adding only mechanical details and control circuits helps cut investment costs compared to buying new automatic machines
Research scope
- Automation mechanical components: slide rails, bearings, timing belt, lead screws
- Electronic components: PLC LE3U, step motor and driver, solenoid, 3phases motor and variable frequency, proximity sensor, yarn sensor
- Design for laser cutting and 3D printing
Research content
The semi-automatic yarn winding machine will be supplemented with 4 main functions:
- Move and fix the plastic core to the spindle
- Cutting the yarn when the roll reach the required size
- Move the finished yarn roll to the storage place
The design and manufacturing process always aims at 3 main goals:
- Easy to use, safe for woker
- Operates stably and convenient to maintain
Research limit
- The machine uses many uncommon components, making maintenance inconvenient
- The controller is a type of circuit board that is not specifically used for industrial machinery, so it is difficult to ensure durability and stability
- Many actuator parts made from PLA plastic that is easily damaged by the unwanted impacts or wear and tear
Research method
In this topic, I used 3 practical research methods
- The first is the observation method Helps support the idea generation process and collect errors during implementation
- Second is the experimental method This method helps me have a more realistic view, detecting errors that cannot be seen on simulation software
- Third is the method of analyzing and summarizing experience After observing and collecting information, the method of analyzing and summarizing experience helped me correct errors.
THEORETICAL FOUNDATION
Automation technology in the textile industry
Textile automation is revolutionizing the fashion industry by enhancing productivity through advanced technology Tasks that were once performed manually are now efficiently executed by machines and software, significantly increasing speed and accuracy while minimizing errors.
For it to work properly, automation must be present throughout the production chain, ensuring optimization of time, greater competitiveness, and authority in the market
Modern machines, software, and other technologies join forces with garment workers to produce much faster and more efficiently
It’s also vital to remember that these improvements came up with Industry 4.0 and, for this reason, textile automation is part of industrial procedures [1].
Description of the Semi-Automatic Yarn Winding Machine
The semi-automatic yarn winding machine includes two main mechanisms: the winding shaft and the yarn guide arm, corresponding to the two functions:
- Moves the yarn guide back and forth along the cone
- Rotates to wind the yarn
Figure 2-1 Winding shaft and yarn guide arm
The winding mechanism operates using a 3-phase motor that directly transmits torque to the winding shaft This shaft utilizes a fabric belt to relay torque to the traverse mechanism, ensuring that the winding shaft and the yarn guide arm function in perfect synchronization.
Figure 2-2 Winding shaft transmit torque to traverse mechanism
After preparing a supply package and a plastic core, the worker will do the 5 following steps to get the filled core with the desired amount
To ensure the yarn remains secure during the initial startup of the machine, position it at the contact point between the plastic core and the rotating shaft.
Figure 2-3.Lay the yarn on the gap between plastic core and winding shaft
To ensure a secure fit, tap the tip of the plastic core, which is anchored from only one side, so that it tightly grips the cone-shaped spindle.
Figure 2-4.Use hammer to tap on the tip of plastic core
- Step 3: Check the yarn position again and press the start button to run the machine
- Through the signal from the sensor, the machine will stop working when the plastic core reach the desired amount
- Step 4: When the machine has stopped, the worker taps on the filled core to separate the plastic core from the rotating shaft
- Step 5: Cutting the yarn to get the finished product and put it in storage
Upgrade idea for semi-automatic yarn winding machine
• Reduce the number of steps to operate the machine from 5 steps to 1 step, which is placing plastic cores into the trough
• Workers only need to intervene with the machine in 3 following situations:
- When the machine has just started: Insert the thread into the spindle then press run
- When the large roll of thread is exhausted and must be replaced with a new one
- When the machine encounters problems
Figure 2-5 Working principle of the upgrading machine
Benefits of upgrading
Upgrading from a semi-automatic to an automatic yarn winding system saves costs compared to buying new machinery It optimizes existing assets economically
By upgrading existing machinery, businesses reduce waste from disposing of old equipment, promoting environmental sustainability and resource efficiency
Upgrading improves operational efficiency by automating processes, ensuring consistent operations, better tension control, and increased productivity
MECHANICAL AND ELECTRICAL SYSTEM DESIGN
Mechanical Design
Regarding the mechanical aspect, the requirements are as follows:
- Sturdy and stable when the machine is in operation
- Able to withstand unexpected impacts
After researching the available materials on the market, I have decided to use extruded aluminum to construct the machine frame
Table 3-1 Table of extruded aluminum information [2]
Figure 3-1 Drawing of the cross-section of 3030 extruded aluminum[2]
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
The machine frame will have basic dimensions of: 750x450x570mm
Figure 3-2 Drawing and dimension of frame
To determine the safety factor of tangential force SolidWorks, it is necessary to determine the forces and their points of application acting on the frame
• Yarn wind machine body weight : 20Kg
• Yarn wind machine body gravity force :
𝑊 = 20 ∗ 9.85 = 197 (𝑁) From reality and easy to calculate force we can assuming that the gravity force of yarn winding machine body is envenly distributed on 2 aluminum bars
• Call 𝑊 1 𝑎𝑛𝑑 𝑊 2 is the gravity force on 2 aluminum bars
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
Determine tension force of the belt
Table 3-2 Parameters to calculate tension force of the belt
The formular to calculate capacity of motor:
1500 = 4.975 (𝑁𝑚) Pulling force on the belt formular :
The belt is only acts from one side of machine so now we have
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
Use solidwork simution to determine the durable of the machine frame
• Step 1 : Define the ground contacting points
Figure 3-3 Define ground contacting points of machine frame in solidwork
• Step 2 : Determine force on 2 bars
Figure 3-4 Apply force on the 1 st bar in solidwork
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
Figure 3-5 Apply on the 2 st bar in solidwork
• Step 3 : Apply material of frame
Figure 3-6 Chosing material in solidwork
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
After running we have the result :
Figure 3-7 Result of yield strength simulation in solidwork
Figure 3-8 Result of safety factor simulation in solidwork
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
Conclusion: the machine frame is qualified to operate
To assess the safety factor of axial force in SolidWorks, it's essential to analyze the components of the belt drive system, which includes evaluating belt tension forces, torque, and pulley characteristics.
Max velocity of the belt v 5m/s
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
Use solidwork to find the safety factor simimar to the tangential force
Figure 3-8 Result of safety factor simulation in solidwork
Conclusion: the machine frame is qualified to operate
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
3.1.2 Design of the plastic core separation mechanism
Separation mechanism is a complex system that requires integrating multiple components to operate effectively To optimize costs, I will choose 3D printing with plastic to implement this part
Table 3-3 Table of 3D printing plastic properties[3]
The storage trough has a spiral shape with a pitch of 240mm per revolution
This design serves three main purposes:
- It conforms to the cone shape of the plastic core
- It creates a slope so that the plastic core can flow due to gravity
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
- To facilitate assembly and 3D printing, the storage trough will be divided into smaller sections interconnected with screws
- This design also allows for adjusting the storage capacity of the plastic cores to meet practical needs by increasing or decreasing the number of smaller troughs
The mechanism consists of two opposing locking bar that operate against each other through an intermediate gear
• The 1 st locking bar is usually in a closed state, keeping the plastic core from slipping out of the trough
• The 2 nd locking bar is usually in an open state, with a distance from the first bar equal to the diameter of one plastic core
Figure 3-10 Separating plastic core system in solidwork
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
When the solenoid is activated, it triggers the upward movement of the first locking bar, enabling the release of one plastic core At the same time, the second locking bar engages, effectively blocking the next plastic core from being released.
• At the end, both locking bar return to their original positions, with one plastic core having slide out and the remaining plastic cores being blocked by the first bar
• After sliding out of the storage trough thanks to the separation mechanism, the plastic core will roll into a horizontal slide chute
• This slide chute has a push rail mechanism underneath, driven by a step motor
• The plastic core will be moved by the push rail mechanism to the holding arm
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
3.1.3 Design of plastic core transportation mechanism
- The plastic core transportation mechanism uses a core holder made from 3D- printed plastic
- The core holder is connected to a rotating shaft driven by a step motor through a timing belt transmission
Figure 3-12 Plastic core transportation mechanism
3.1.4 Design of live center mechanism
The live center mechanism plays an important role in keeping the plastic core stable during rotation and creating friction between the rotating shaft and the plastic core
The live center mechanism include 6 components:
- 1 st is the conical rotating shaft, which directly contacts the plastic core
- 2 nd is two 6800 bearings, which fix the conical rotating shaft and reduce friction during rotation
- 3 rd is 6800 bearing housing, which fixes the position of the two bearings and slides axially within the main housing
- 4 th is spring, which provides pushing force for the 6800 bearing sleeve
- 5 th is the main housing serves as a sliding guide for the bearing sleeve and mounts components onto the base, which secures the components to the linear shaft
- 6 th The linear shaft slides on linear bearings, driven by a lead screw control by a step motor
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
Figure 3-13 Live center mechanism structure
The live center mechanism can move axially thanks to the lead screw driven by a step motor through timing belt transmission
The lead screw can ensure that the force exerted by the live center mechanism on the plastic core is more controlled and stable during the winding process
Figure 3-14 Driven of live center mechanism
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
3.1.5 Design of yarn pushing hand mechanism
The function of the yarn pushing mechanism is also very important, with the two following main functions:
- Push the yarn to the thermal cutting position
- Push the yarn to the rotating shaft position to supply a new core
Figure 3-15 Operation of yarn pushing hand
The driving mechanism of the yarn pushing mechanism is identical to the live center mechanism when using a lead screw driven by a stepper motor through a synchronous belt transmission
Figure 3-16 Yarn pushing hand mechanism
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
3.1.6 Design of finish product transportation mechanism
- The main function of the transport arm is to move the finished bobbin from the drop-down centering unit to the finished product storage bin
- Same as the holding am, the fishnish product transport arm is connected to a rotating shaft driven by a step motor through a timing belt transmission
Figure 3-17 Fisnish product transport hand structure
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
3.1.7 Belt transmission system of the plastic core handling system
- Transmit torque form step motors to the rotating shafts and leadscrew
=> XL belt transmission series can meet theses requirements
Table 3-4 Table of XL belt transmission parameter
In all of the actuator that use step motor, the finished product transport hand is require highest torque
Figure 3-18 Finished product transport hand dimention
Maximum weight of the finished product is up to 500g (5N)
The distant from the product to the center of shalft is 125mm (0.125m)
Ignore the weight of plastic hand hand rotating shalf
The torque created by the finished product transport hand is :
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
Maximum torque of step motor 57 is lager than the maximum torque requirement
𝑀 𝑚𝑜𝑡𝑜𝑟 = 1.8𝑁𝑚 > 𝑀 = 0.625 Nm For the transport machanism, increasing the transmission ratio so the to increase the accuracy and smooth operatipon : Ratio = 1 : 5
- Distant between motor and rotating shaft : 𝑎 = 110 (𝑚𝑚)
• For the live center and cutting hand machanism, that using leadscrew mechanism Choose the transmission ratio = 1 : 1
- Distant between motor and rotating shaft : 𝑎 = 64.3 (𝑚𝑚)
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
- 1 st The plastic core separation release 1 core to the slide chute
- 2 nd Feeding core holder by 1 plastic core
Figure 3-18 Feeding the holding arm
- 3 rd Holding arm move the plastic core the live center mechanism
- 4 th The live center mechanism comes out and pushes the plastic fix with the winding shaft and also making the yarn is clamped
Figure 3-19 Fix the plastic core
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
- 5 th The yarn winding machine operates until the core is reach the setting size
- 6 th When the thread winding machine stops, the live center mechanism will return to its original position, causing the finished yarn spool to fall into the finish product chute
- 7 th The transport arm rotates outward at an angle of about 45 degrees At this time, the thread will be stretched horizontally
- 8 th The yarn pushing arm moves out, pressing the yarn tightly against the winding shaft, and close to the thermal cutting
Figure 3-20 Pushing the yarn to winding shaft
- 9 th The heat cutting process is activated
- 10 th The transport arm rotates outward one more time for the core rolling to the storage bin
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
Electrical control system design
The central controller must meet the following requirements:
- Can be controlled by both push buttons and HMI screen
- Receive and process signals from proximity sensors, obstacle sensors, and yarn sensors
- Generate pulses to control stepper motors
- Control the on and off status of the relay
- Communication with variable frequency through Rs485 method
=> PLC LE3U meets the above requirements
LE3U PLC is compatible with Mitsubishi GX-Developer/GX-WORK2 software and supports human-machine interface connection, making it equivalent to the Mitsubishi FX3U PLC
The LE3U PLC features robust ladder programming capabilities, allowing for efficient program downloading and monitoring through its dedicated programming port for seamless communication with human-machine interfaces Equipped with an industrial-grade 32-bit MCU, the LE3U PLC offers superior anti-interference performance and significantly enhanced processing speed compared to the FX3U PLC.
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
There are 3 important notes when writing and loading programs for PLC LE3U when using GX Work software
- 1 st When selecting the PLC model in the software it is FX3U
Figure 3-22 Type of PLC in GxWork 2
- 2 nd when downloading the program, choose a transmission speed of 38.4kbps to be compatible with LE3U
Figure 3-23 Choose baud rate 38.4 kbps
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
- 3 rd Use USB to serial RS232 cable to load the program from the computer
Figure 3-24 USB to serial Rs232 cable
- Determine the position for linear mechanisms: lead screw, slide rail, roating shaft
- Determine the finished yarn roll size
Table 3-4 Table of PL-05N proximity sensor properties[5]
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
Table 3-5 Table of LJ8A proximity sensor properties[6]
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
Function: Detect plastic core on winding shaft
Table 3-6 Table of obstacle sensor parameters
Figure 3-27 Obstacle sensor wires connection
Function: Detect yarn, send signal to PLC in cases when yarn is broken or frozen
Table 3-7 Table of obstacle sensor parameters
Figure 3-28 Yarn sensor wires connection
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
- Drives the lead screw controls the position of the cutting arm and the live center mechanism
- Drives the rotary shaft of the plastic core holding arm and the finished product trasport arm
- Control belt drive of slide rails
- Position and speed can be controlled by PLC
=> Stepper motor size 57 meets the above requirements
Table 3-8 Table of step motor parameters[7]
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
- Drives the winding shaft and yarn guiding arm of the yarn winding machine Requirement:
- The of old machines is using one 2 Kw motor for drive 5 yarn winding machines
=> The capacity needed for 1 machine is 0.4 Kw
=> Hyosung 0.75kW 3-phase electric motor meets the above requirement
Table 3-9 Table of 3 phases motor parameters
With the 220V variable frequency, it is necessary to make the motor in delta connection
Figure 3-30 Delta connection of 3 phases motor
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
- Create thrust for the plastic core separator
=> Solenoid KK – 1264B meets the above requirements
Table 3-10 Table of solenoid parameters [8]
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
3.2.4 Driver and Variable frequency devices
- Control a stepper motor has a maximum current of 3A
- Operates in pulse and direction supply mode
=> DM542 with a maximum current of 4.2A can meet the above requirements
Table 3-11 Table of DM542 driver parameters
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
- The input power is 1 phases 220V
- The output power is 3 phases 220V or 380V
=> GD20-1R5G-S2 inverter can meet the above requirements
Table 3-12 Table of GD20 variable frequency parameters[9]
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
- Adjust the maximum frequency of the inverter
- Display error when a problem occurs
- Displays the number of finished yarn rolls
- Able to communicate with LE3U board
- Compact size, lightweight, high durability
=> HMI OP320 can meet all of these functions and requirements
CHAPTER 3 MECHANICAL AND ELECTRICAL SYSTEM DESIGN
Table 3-13 Table of HMI OP320 parameters
To program for HMI OP320, we use OP20 Edit Tool V8 software
This is the OP20 Edit Tool V8 software interface
Figure 3-35 OP20 Edit tool interface
IMPLEMENTATION & RESULTS
Implementation process
Based on the designed model, calculation and simulation on Solidworks software to process the details
Install the aluminum frame then fix the semi-automatic machine body to the the frame
Figure 4.1 Aluminum frame and Yarn winding machine top view
Install the plastic core separation mechanism and slide rails
Figure 4.2 Plastic core separation & slide chute
Install the plastic core transport arm, finished product transport arm, and yarn pusher arm
Figure 4.3 Install the iron plate and slide shalft on frame
After checking and adjusting the details for smooth operation, I proceed to assemble the stepper motors, solenoids and timming belt transmissions
Proximity sensors are designed to able adjust the desired operating distance
Electrical equipment needs to be installed neatly and securely to avoid short circuits or loose contacts during use
After installing the electrical equipment and ensuring its reliability, the next step is to program the machine to operate
Figure 4.8 Program in GX-Work 2
The program are written on Gxwork 2 with 1449 steps, deviding into 4 main contents:
Difficulties encountered
- Some structures collided with each other, so they had to be redesigned
- 3D printed plastic is not sturdy so it must be increased in thickness
- There are many small nooks and crannies that make installation difficult
- Some components are difficult to buy on the market and take time to search and buy
Results achieved
- The machine can operate correctly in theory, equipped with all the features as stated
- The machine can active automatic with just 3 buttons and display status on the HMI
- The details are installed relatively firmly and neatly
- The maximum efficiency is 12 rolls / hour
CONCLUSION AND RECOMMENDATION
Conclusion
- Upgraded products are cheaper than new models on the market
- Components such as semi-automatic yarn winding machine body and 3-phase motor can be reused to help reduce waste
- During the process of implementing the model, I feel like I have made progress in terms of thinking, working style and other soft skills
- To complete the model, I also applied relevant knowledge learned in school and it this process helped me a lot in remembering knowledge, applying it in practice
The operating mechanisms are still cumbersome and have many details, causing time wasting during the manufacturing and installation process
Many details are still made of PLA plastic, which does not guarantee rigidity
Recommendation
- The structures can be further optimized to be applicable on a large scale
- Research more automatic large thread roll feeding mechanism to increase efficiency
- Change the extruded aluminum frame to iron frame optimize costs and increase stability
- Upgrade the genuine circuit board and replace PLA plastic parts with CNC aluminum to make the machine more stable and durable
Discover the benefits of implementing textile automation in your business, including enhanced efficiency through computerized data monitoring and automatic processes Learn how these innovations can streamline operations and improve productivity in the textile industry For more insights, visit Audaces' blog on textile automation.
[2] STAVIAN Industrial metal NHÔM ĐỊNH HÌNH 30×30 LÀ GÌ? BẢNG GIÁ, THÔNG SỐ KỸ THUẬT https://stavianmetal.com/nhom-dinh-hinh-30-30/
[3] Xometry All About PLA 3D Printing Filament https://www.xometry.com/resources/3d-printing/pla-3d-printing-filament/
[4] LOLLETTE Automation Store LE3U PLC https://www.lollette.com/le3u-plc-controller
[5] Fotek Automation PL-05P http://fotek.com.vn/san-pham/pl05p-165.html
[6] Fotek Automation PM08-02N http://fotek.com.vn/san-pham/pm0802n-166.html
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[9] Cơ điện hải âu Biến tần INVT GD20-1R5G-S2 1.5kW 1 Pha 220V https://codienhaiau.com/product/bien-tan-invt-gd20-1r5g-s2-1-5kw-1-pha/
[2] [10] LOLLETTE OP320-A HMI (Human-Machine Interface) Panel Display https://www.lollette.com/led-text-display-op320.html
- Activate the machine to running
- Stop all of the actuator when it running
- Stop machine to do something
- Stop when the machine encoutered problem
- Set all of the actuators move to home positon Use cases
- Stop all of the actuator by cutting power supply Use cases
- Another buttons is not working
Page 1 : Display status of machine and number of fisnished product
Page 2 : Control the live center mechanism and 3 phases motor by hand
User need to press RESTART button to set home all of the actuator
The restart process is woking, user need to wait for another actions
-53- Restarting process is complete, user press START button for running
The machine is on stop mode, user press START button to contine running
-54- The yarn is broken, red lamp blinking
The plastic core is empty or feeding process enteroured problem