Sewing Machine in Garment Section
Textile mills are facing energy wastage problem in their garment section. Most of the sewing machines of garment section are arranged in columns and all station lights are kept ON continuously even when just one worker is working. Moreover, garment sectors are unable to monitor the efficiency of their machines and workers. Garment sections need an energy efficient control and monitoring system for their workers. Cost is an actual factor for them. To achieve this goal, different sensing mechanism has been tried but all of them have their intermittencies. Then current sensing mechanism is designed, this method is based on flux control method. Flux of the Sewing machines sensed for the operating and controlling of the station light and optional fan. Whenever the worker starts machine, lightand optional fan will turn ON and it will ON until the worker not work in the desirable specified time. This time delay and machine controlling is done through 8051 microcontroller. The complete system module makes master slave mechanism. Data transfer to computer is accomplished through microcontroller, serial communication and R.F transmitter. The receiver will receive data which are transmitted to computer using serial communication (MAX232). The data receiving protocol will be running there. This data is saved in an excel document which contains the complete record of the working time of the machines VS Sewing Machines
Most of the textile mills have a fixed asset base of USD 20.00 million, annual turnover of USD 60.00 million and 2500 employees [5]. These textile mills are facing energy wastage and shortage problem in their garment section [6]. One of the reason is that sewing machines are arranged in columns and all station lights continuously are kept ON, even if just one worker is working and more over they didn’t able to monitor worker how much they efficiently work. That’s why they want energy efficient control and monitoring system for their machines [7]. Cost must be considered in that system [7, 8]. The design proposed in the paper has two major subparts. The first part involves controlling the station light by knowing the presence of workers on the machine which shown their working status and performance. The second part involves sending data towards manager room and then extracting the data into the excel format. For achieving this target, various different sensing mechanisms have been tried, but most of them are not working efficiently and properly, which include Passive infrared (PIR) sensor, R.F. sensor, ultrasonic sensor etc. [9, 10]. When other conventional sensors were failed to deliver the results then current sensing mechanism is designed which works on the sewing machine’s working status through using flux of the machine. On the other hand, monitoring and sending data towards the manager room is the real challenge because there were four hundred machines need to synchronize in addition the data need to send wirelessly. For synchronizing the machine there is thirty-one masters is made, each master connected to thirty slaves and each master link to single master, which communicate all the data towards the manager. Although the data can be transmitted through various ways such as ZigBee device, wireless super regeneration transmission module, etc., but super regenerative wireless transmission module is opted for transmission of data https://www.vssewingmachine.in/
Solemnly aim of this paper is to present the model design for sewing machine which ultimately helps in energy saving by turning off the redundant tube lights. As per our subject industry, master textile, there are four hundred sewing machines present there and hundreds of stations control through single breaker. Controlling the station light can save tremendous amount of energy because most of the stations used are in idle condition and station lights are turned ON with no reason. Unlike master textile, there is various energy saving opportunities that exist in every textile plant in a various way. The main purport is to save the overall unit cost for better profit margins. Overall electricity consumption and electricity expenditure is one of the main considerations during costing. We can’t share exact design for the industrial patient issue of industry. Manual switching control system installed for the sewing machine but the intermittency is that it’s depend upon the worker, moreover, it’s lagging the monitoring system
Complete system architecture is presented in which includes single master and master’s slave scheme. The slave is connected with machine and station light. Whenever the worker starts the machine, slave senses the machine current and turns ON the light and optional fan for a specific period of a time. ON light status is adjusted through programming. Master slaves communicate through RS485. The entire master’s takes data from all the connected slaves and sends it to the single master, afterword single send data to receiver using a wireless transmitter. A receiver receives the data and sends it toward the managerial computer. Data gets processed at the receiver end which sends it to the computer through RS232. If the system is turned off, then data will be saved in EEPROM. The data gets transmitted, when the computer turns ON. Moreover, data is saved in excel file