COMPUTERS AND AUTOMATION IN WEAVING

Southeast University
School of Science & Engineering, Department of Textile Engineering

COMPUTERS AND AUTOMATION IN WEAVING

Md. Fazley Elahi
Assistant Professor
Dept. of Textile Engineering


Computers and Automation
Integrated artificial intelligence is incorporated in most of the modern weaving machines.
Modern electronics with microprocessors, integrated in the machine, monitor, control, regulate and
optimize all major weaving machine functions.
The central microprocessor monitors and controls the weaving process.
The touch screen terminal is used as the interface between the operator and the machine. The
terminal acts as the interface between personnel and the machine. Corresponding to the varying
information requirements, the microprocessor control provides specific terminal functions for
operators, supervisors and managers. Setting data may be transferred from one machine to
another with a memory card. If no setting data is available for a style which had not been woven
previously, the microprocessor can calculate standard parameters from the entered fabric
specification and transfer them automatically to the electronically controlled function units. Twoway communications with production management systems or production data collection systems
are possible with suitable interfaces.
Md. Fazley ELAHI

Computer & Automation in Weaving

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Today's modern weaving machines offer high operational reliability with centralized
microprocessor control. These operations were included in the previous chapters for
each particular machine. Some examples of automation and electronic control are:
 Electronically controlled warp let off provides constant warp tension.
 Electronically controlled cloth take-up maintains the accurate cloth weight.
 Electronically controlled color selection allows picking of multifilling colors.
 Electronically controlled yarn brake reduces filling breaks and waste and provides
 constant filling tension.
 Menu guided operation at the terminal assists the Quick Style Change.
 Interfaces for two-way communication with modern systems for plant management
 and production data collection.

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Programming and Archiving Systems
Weaving machine manufacturers developed user friendly programming and archiving
systems for the weave room. With these systems, the pattern data and the
machine settings can be programmed in the office with the aid of a PC from where
they are transferred onto the machine. These systems offer the following
advantages:
 shortening the resetting and cycling times
 increasing efficiency
 improving reproducibility

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Electronic Spare Parts Catalog
Today, weaving machine manufacturers provide spare part catalogs in electronic
formats such as CD-ROM. A CD-ROM weighing 20 g and featuring a diameter of 12
cm can store information of a catalog comprising of some 13,000 pages of paper,
weighing 50 kilograms. From an ecological point of view, this new development
offers a big advantage.

Md. Fazley ELAHI


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Electronic Direct Ordering System (EDOS)
The just-in-time philosophy is becoming increasingly evident and manufacturers
are reducing their spare part reserves to absolute minimum levels. With today's
modern, capital intensive and highly productive weaving machines, the cost of lost
production is much higher than that incurred for spares. Furthermore, the
requirement which depends on the employed raw weaving materials and external
influences can be very irregular. The consequences are shorter deadlines with
greater responsibility, which can only be overcome by tightening up the flow of
information and material between the customer and the supplier.

Md. Fazley ELAHI


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Electronic Direct Ordering System makes it easier for customers to order parts
and supplementary parts. The electronic transfer of data servants’ transmission
errors and offers the assurance that the customer will quickly receive the correct
parts. The system accelerates and channels the flow of information and goods
of an order on its way from the customer to the supplier and back again. For the
electronic ordering of spare parts, the customer needs a commercial type PC, a
modem, a printer and the necessary software.
With the EDOS systems, the customer can receive complete, up-to-date and
accurate information quickly. The high transmission quality is also beneficial.
Ultimately, the customer receives his urgently required parts quicker: the order
cycle is reduced. The electronic processing of the order data reduce the
possibility of typographical and transmission errors. The customer does not
have to enter and check the majority of the data with each other. The simplified
book keeping and order monitoring leads to reduction in cost.
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The customer selects the parts that he wishes to order from the standard set of
data; he sees all the necessary data and complements them with the required
amount and mode of delivery. The data are then transmitted by modem to the
subsidiary and passed onto the head office. After a short time and along the same
route, he receives the confirmation of order, with price and information concerning
the readiness for dispatch. He knows already that he will receive the right parts
and when he can expect them.

Md. Fazley ELAHI


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Computer Aided Design (CAD) and Computer Aided
Manufacturing (CAM)
Today's CAD/CAM technology allows transmission of fabric design from computer
screen to the machine. CAD/CAM saves product development and manufacturing
time, provides quicker response with good accuracy and quality. Pattern changes
and modifications are done easier and quicker.
There are various configurations and setups of CAD/CAM systems. As an example,
in one configuration for woven terry fabrics, the artwork produced by a stylist is
scanned into a workstation. Then, the design parameters are entered for a specific
fabric style. Parameters for each fabric style are stored in a database. The
scanned-in artwork is edited and a weave is selected from a database. Colors are
displayed on the computer screen. The pattern file developed is digitized and
stored in a diskette for subsequent downloading into the jacquard machine
controller on the weaving machine. Through the workstation-printer interface,
assimilation of the fabric can be printed out. Thus, the terry towel can be seen in
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Md. Fazley ELAHI
virtual reality


In a more scientific approach, CAD of fiber, yarn and fabric simulations can be
done based on mathematical and physical principles. Thin and thick places and
other irregularities can be represented in the yarn depending on the simulated
manufacturing model. Using the 3-D image of the yarn, the resulting woven fabric
can be simulated. Visualizing the physical characteristics of yarn on the screen
before the yarn is manufactured provides significant advantages in reducing R&D
and prototype manufacturing time of fabrics. The manufacturer can determine the
suitability of a yarn in a fabric a lot faster with less cost. Even the wash down
effects on fabrics can be simulated with computers.

Md. Fazley ELAHI


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With the growing demands made on fabric quality and efficiency of the weaving
machines, their functionality rests increasingly on electronics and information
systems along with mechanics. Today, fabric design is developed on the
computer and transferred to the weaving machine in a memory card.
The building blocks of such a CAD/CAM system are as follows:
Weaving Data Archive:
o managing and archiving all weaving data records
o creating new weaving data
o Interface for importing new pattern data from various CAD programs.

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o
o
o
o
o

 Weaving Data Record:
Diagrammatic representation of harness frame and color control as well as
special functions. Numeric representation of filling density and pile height
developing and modifying pattern data as:
pattern for card punching (also electronic)
color pattern
special functions
electronically controlled cloth take-up
dynamic pile control

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o
o
o
o

 Parameters:
Programming of the electronically controlled functional units on the weaving
machine developing or modifying the electronic machine settings as
warp let-off functions
data for the electronically controlled filling yarn brake
controlled fabric fell correction

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Data Transfer:
Transferring the weaving data to the memory card (MC) or back with the aid of the
data carrier, the weaving data are transferred to a memory card. After the memory
card has been loaded with one or more sets of weaving data, the memory card is
passed on to the weave room staff who transfer the data to the weaving machines
by means of the data carrier. After fine optimizing of the weaving data on the
machine terminal, the data can be archived in the PAS via the data carrier, thus
ensuring the reproducibility of the fabric quality.

Md. Fazley ELAHI


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Computer Based Training
Today's fast and powerful computers enable multimedia-based training
programs. These programs allow improvements of the quality standard,
motivation of the staff members as well as reduction of training costs. Multimedia
based training offers the possibility of passing on knowledge within the industrial
sector with large quantities of visual material. The computer based training (CBT)
system teaches operation and maintenance of the weaving machine by means of
full-screen video, animation, audio, pictures, diagrams and text. It enables job
targeted learning and the material taught can be immediately rested on the
machine. It is also possible to repeat such exercises as often as necessary and
each student is given the same explanation, irrespective of the environment.

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Computer Based Training (continued)
Comprehensive training courses can thus be considerably shortened. Function,
operation and maintenance of the weaving machines are presented in an effective
way, since the students have normally no opportunity to watch these on the
machine. The entire material is stored on CD-ROM disks and can be adapted
individually and customer-specifically on training PCs. The interactive CBT can be
used at anytime and anywhere, independent of the instructor, be it on the machine
the office or at home. Service and sales engineers can take CBT with them in their
hand luggage. The modular structure of the CBT system affords learning in
appropriate steps. The students are able to call the individual learning steps and to
repeat them as often as they wish, without specific PC experience. Concerning
presentation, they can choose between video film, animation or still photography,
each one accompanied by spoken text.
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The latter can be displayed and printed. A multitude of test and qualification
possibilities enable detailed control of the learning success. The lecturer who is
responsible for the training obtains an up-to-date and objective survey on the
learning success of all participants of the course, who, in turn, have the possibility
to watch the actions carried on the machine through laptop PC.
Even though the preparation of CBT programs involves considerable expenditure,
the overall costs for the entire learning package are far below those for training the
customer personnel in the conventional way.

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For CBT training, a PC configuration is required on which CD-ROMs
can be run. Several PCs can be networked with each other. A training
manager supervises the learning progress of the trainees. An
advantage of CBT is that it is always available when necessary and
when there is time for learning. CBT constitutes a tool that enables
internationally active enterprises to train their coworkers and
customer employees, on a global basis, with always the same
standard. This guarantees that each production location delivers the
same product quality.

Md. Fazley ELAHI


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Technology Support Centers
Some weaving machine builders are offering technical support to their
customers through feasibility studies, weaving trials, etc., in research
weaving facilities. Service and customer weaving trials are conducted in
these facilities.
With the weaving trials, fiber and yarn manufacturers can determine
whether or not, and at which weaving machine speeds, the desired
styles can be optimally produced on the weaving machines. In these
research centers, new fabrics can be developed and weaving problems
can be solved.

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





The filling insertion trials reveal the expected frequency of filling stoppages as well as the
suitability of the yarn for the corresponding type of weaving machine. The yarns and
fabrics are inspected for possible defects as well.
Machine manufacturers also help customers to meet the new demands with the existing
machinery. They provide services and studies for retrofitting, conversion, customer
oriented solutions for special equipment, special fabrics and accessory and auxiliary
components. The following changes of machine specifications are demanded most
frequently:
conversion from single pick to weft mixer
increasing the number of harnesses
conversion from dobby to jacquard machine
equipment for heavy fabrics
increasing the warp beam diameter

Md. Fazley ELAHI


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COMPUTERS AND AUTOMATION IN WEAVING

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