This presentation is about the automation of draw frame machine used in textile industries with B&R PLC.

1. AUTOMATION OF DRAW FRAME
MACHINE USING B&R PLC
Prepared By:
Prof. Sandeep J. Rajput
Assist. Prof., EC Dept.
HCET,Sidhpur.

2. INTRODUCTION
• This presentation is about Automation of Draw Frame Machine using B&R PLC.
• The machine which makes the strong sliver by twisting the number of thin cotton
threads feeds from the cans of feed creel is called Draw Frame machine.
• This machine is a substitution of the conventional draw frame machine to reduce
the cost.
• The Yarn material produced by conventional draw frame is of higher cost which all
the customers can’t afford.
• In order to reduce the cost of the fabric material to satisfy the customers in cost
with almost same quality the machine is used.
• This new approach has lower cost because it uses less component compare to the
conventional draw frame machine .
• Main aim of is approach to add Indian customer specific features & reduce the cost
of TMS-2 system and NOM3 relay module which used in control panel by
replacing B&R PLC.

3. SCHEMATIC BLOCK DIAGRAM OF CONTROL PANEL OF DRAW FRAM MACHINE

4. COMPONENT LAYOUT OF CONTROL PANEL
1: TMS, Trutzschler
micro-computer
system
2: Key switch for
service mode
3: Power supply
servo module
4: Rotary can plate
drive servo module,
SM10
5: Rotary sliver feed
creel drive servo
module, SM10
6: Delivery drive
servo module,
SM20

5. MICRO-COMPUTER SYSTEM

6. INPUT CONFIGURATION PORT:0&1
INPUT APPLICATION RELATED COMPONENTS
E0.0 FUSE MONITERING FUSE F010,F030
E0.1 SAFETY LOOP O.K. NOM3 A200
E0.2 SAFETY EQUIPMENT OK NOM3 A200
E0.3 MOTOR PROTECTION SWITCH MPCB Q100,Q115,Q120,Q130
E0.4 EMERGENCY STOP SELECTION SWT S210,S250
E0.5 SAFETY LIMIT SWITCH PROTECTIVE HOODS SAFETY SWITCH S230,S240
E0.6 COMPRESSED AIR O.K CHANGE OVER CONTACT B5
E0.7 PRESSURE MONITORING,CENTRAL SUCTION CHANGE OVER CONTACT B570
E1.0 DRAFTING SYSTEM CLOSED SENSOR B436
E1.1
E1.2
E1.3 DRAFTING SYSTEM COVER CLOSED SAFETY SWITCH S450
E1.4 DRAFTING SYSTEM LAP 2-SENSOR A440,A441
E1.5 MONITORING O.K. SENSOR B431
E1.6 DELIVERY ROLLS O.K. SENSOR B433
E1.7 COILER PLATE AREA OK SENSOR B432

7. INPUT CONFIGURATION PORT:2&3
INPUT APPLICATION RELATED COMPONENTS
E2.0 NO SLIVER BREAK SENSOR B468,SENSOR B467
E2.1 NO SLIVER BREAK SENSOR B466
E2.2 NO SLIVER BREAK SENSOR B465
E2.3 NO SLIVER BREAK SENSOR B463,B462,B461,B464
E2.4 3WAY KEYBOARD START/THREADING STARTA 520
E2.5 3WAY KEYBOARD INCHING MODE TIP A520,TIP A510
E2.6 3WAY KEYBOARD START START 510
E2.7 3WAY KEYBOARD STOP STOPA520,STOPA510
E3.0 SERVICE SWITCH (SERVICE OFF) NOM3 A200
E3.1 EXTERNAL EMERGENCY STOP
E3.2
E3.3 TURNSTILE POSITION SENSOR B106
E3.4 CAN STOPPER EXTENDED SENSOR B131
E3.5 EMPTY CAN AVAILABLE SAFETY LIMIT SWITCH S110
E3.6 START CAN FEEDWAY DRIVE SAFETY LIMIT SWITCH S132
E3.7 CAN MAGAZINE IS FULL SAFETY LIMIT SWITCH B109

8. OUTPUT CONFIGURATION PORT:0&1
OUTPUT APPLICATION RELATED COMPONENTS
A0.0 ENABLING SAFETY EQUIPMENT SAFETY LIMIT SWITCH S230,S240
A0.1 ENABLING IMPULSE SAFETY EQUIPMENT NOM3 A200
A0.2
A0.3
A0.4 FLASH LAMP WARNING CC CHANGING FLASH LAMP YELLOW H581
A0.5 SIGNAL LAMP NORMAL MODE (GREEN) SIGNAL LAMP GREEN H580
A0.6 SIGNAL LAMP WARNING (YELLOW) SIGNAL LAMP YELLOW H580
A0.7 SIGNAL LAMP FAULT (RED) SIGNAL LAMP RED H580
A1.0
A1.1 LOAD DRAFTING SYSTEM SOLENOIED VALVE Y3
A1.2 THREAD WEB GUIDE SOLENOIED VALVE Y1
A1.3
A1.4 LOAD TOP ROLL (SLIVER CUT) SOLENOIED VALVE Y6
A1.5
A1.6
A1.7

9. OUTPUT CONFIGURATION PORT:2&3
OUTPUT APPLICATION RELATED COMPONENTS
A2.0 FAN IN FRAME CLOCKWISE RELAY K040
A2.1 FAN IN FRAME COUNTERCLOCKWISE RELAY K041
A2.2 CONTROL CABINET FAN RELAY K003
A2.3 SUCTION FAN ON RELAY K120
A2.4 SUCTION FLAP CENTRAL SUCTION SOLENOIED VALVE Y571
A2.5
A2.6
A2.7
A3.0
A3.1
A3.2
A3.3 TURNSTILE DRIVE CLOCKWISE RELAY K116,RELAY K115
A3.4 TURNSTILE DRIVE COUNTERCLOCKWISE RELAY K116,RELAY K115
A3.5 CAN STOPER EXTENDED SOLENOIED VALVE Y5
A3.6 CAN FEEDWAY DRIVE RELAY K130
A3.7

10. MODES OF OPERATION
Working mode
• In working mode the machine does all the routine work for which it was
programmed . As the inputs are provided to the PLC the output is taken
from it. There are basically 16 inputs & 16 outputs provided in the PLC. If
more are needed than we can also use the expansion module.
• In this mode there are sensors which sense the inputs and provide them to
the PLC through which we can get the output. There are a total of nine
sensors for doing the work.
• The basic function of the machine is to count, even & uncurl the raw slivers
that are provided to the machine. The input slivers are provided to it from
the carding machine which is used to take the dust out from the cotton.
• Multiple number of slivers are provided to the machine through the feed
crill. All of these slivers are than compressed into one sliver by the drawing
process. After this the slivers are carried out where they are stored in the
bucket in the form of output.

11. MODES OF OPERATION
Service mode
• Within the scope of servicing, the current condition & the functionality of
components are assessed. Whatever maintenance & repair work is
necessary is determined from this condition.
• In this operating mode we can select & test individual components. In
some cases additional information is seen, such as rotary speeds,
connections or the corresponding sensors. We can activate the service
mode through the B&R PLC
• Now for selecting the component to test we can select any of it by
pressing the enter button on the PLC. The components which we can test
are Motors M003, M004, M115, M120, and M130. Valves Y1, Y3/Y6,
Y5, Y6, Y571. Sensors A460…A468, B431, B432, B433, B436, S110,
S132, S230, S240, S450. L.E.D. RED, YELLOW, GREEN.
• All the defective components after the service mode are to be replaced by
the new ones. The other components which are up to date should be
cleaned perfectly. Then the machine should be fully assembled back as it
was before. We can manually or automatically service the machine
through the service mode.

12. PROGRAMMING FLOW GRAPH OF
SERVICE MODE VIA B&R PLC
B & R

13. MAIN MENU FLOW GRAFH

14. VALVE TEST FLOW GRAFH

15. MOTOR TEST FLOW GRAFH

16. DRIVE TEST FLOW GRAFH

17. SENSOR TEST FLOW GRAFH

18. LED TEST FLOW GRAFH

19. HUMAN MACHINE INTERFACE

20. 1. MODE SELECTION
MACHINE MODE SELECT 1 = Go for Working Mode
TD 02_MODE
0/1 0 = Go for Test Mode
WORKING/TEST=1/0
2. AUTO_MANUAL
TEST MODE 1 = Go for Auto mode
TD 02_MODE
0/1
AUTO/MANUAL=1/0 0 = Manual Mode
3. GO TO
0. MOTOR TEST 5.I/P STATUS F1  Auto_manual
1. VALVE TEST 6.O/P SATUS
2. DRIVE TEST 7. D & T
3. SENSOR TES 8. RESTART F2  Auto_manual
4. SPECIAL TES 9. WARNING

21. 4. MOTOR SELECTION
MOTOR 003 F1  GO TO
MOTOR 004
MOTOR 115
MOTOR 120
MOTOR 130 F2  GO TO
5 .VALVE TEST
VALVE Y1 F1  GO TO
VALVE Y3
VALVE Y5
VALVE Y6
VALVE 571 F2  GO TO
6. SENSOR TEST
B132 S450 F1  GO TO
B431 S110
B432 S230
B433 S240
B436 F2  GO TO

22. 7. INPUT STATUS
I/P1 I/P6 F1  GO TO
I/P2 I/P7
I/P3 I/P8
I/P4 I/P9
I/P5 I/P10 F2  GO TO
8. OUTPUT STATUS
O/P 1 O/P 6 F1  Go TO
O/P 2 O/P 7
O/P 3 O/P 8
O/P 4 O/P 9
O/P 5 O/P 10 F2  GO TO
9. DATE & TIME
DATE DD/MM/YYYY F1  GO TO
**/**/****
TIME: HH/MM/SS
**/**/** F2  GO TO

23. 11. RESTART MODE
*** Restart Mode *** F1  GO TO
1. Restart Target : 0
2. Erase all Data and
Restart Target : 0 F2  GO TO
To come out of hanging situation of LAP COMMANDER, Without
Switching off the Main Switch , if you want to start the target then make
Restart target = 1.
2nd is 1 then it will Erase all set parameters and retentive data. After it all the
parameterization will be done again.
12. WARNING
MOTOR 003 F1  GO TO
MOTOR 004
MOTOR 115
MOTOR 120
MOTOR 130 F2  GO TO

24. B&R PROGRAMMING MODULES

25. B&R PROGRAMMING MODULES
Cyclic Program #1-[10ms]
• Input Initialization
• Output Initialization
• Variable Initialization
• Manual Mode Service Program
• Auto Mode Service Program
• Program for Working Mode
Cyclic program #2-[10ms]
• Program for warning
• Program for bitmap
• Program for password
• Program for reset
Cyclic program #3-[50ms]
• Program for date and time
• Program for key and led test

26. BLOCK DIAGRAM OF SIMULATOR
Power
Supply
Relays
Power
Terminal
Switch
Mode
Power
Supply
MCB
Power Motor Protection
Circuit Breaker
PLCOutput
Lamps
Input Push Buttons
Power
Switch
Input Port
Output Port Power
Supply
MCB
Contactor

27. DIGITAL I/P ASSIGNMENT
Terminal No. Address Description
01 - (0V DC)
02 + (24V DC)
03 I1 Not used
04 I2 To start sensor B431
05 I3 To start sensor B432
06 I4 To start sensor B433
07 I5 To start sensor B436
08 I6 To start sensor s110
09 I7 To start sensor s230
10 I8 To start sensor s240
11 I9 To start sensor s450
12 I10 To select Auto/manual
13 I11 Warning in M130
14 I12 Not used
15 I13 Not used
16 I14 Not used
17 I15 Not used
18 I16

28. DIGITAL O/P ASSIGNMENT
Terminal
No.
Address Description
01 - (0V DC)
02 + (24V DC)
03 Q1 To Start M003
04 Q2 To Start M004
05 Q3 To Start M115
06 Q4 To Start M120
07 Q5 To Start M130
08 Q6 To Start Y571
09 Q7 To Start Y6
10 Q8 To Start Y5
11 Q9 To Start Y3
12 Q10 To Start Y1
13 Q11 To Indicate ERROR
14 Q12 To Indicate WARNING
15 Q13 To Indicate RUNNING
16 Q14
17 Q15
18 Q16

29. SCHEMETIC DIAGRAM OF SIMULATOR

30. 3 PHASE MOTOR INTERFACING

31. SINGLE PHASE MOTOR INTERFACING

32. PLC O/P TO RELAY INTERFACING

33. SENSOR TO I/P INTERFACING

34. APPLICATION
• Machine TD02 has two mode of programming Working mode and Service
mode in working mode machine automatically sense the drive position and
material status and these information is given to the PLC and according to the
input condition and machine working PLC operate motors, drives and valves
when in Service mode there are two mode Manual mode and Auto mode.
• In Manual mode we have to independently select each and every motor, drive,
sensor, valve and lamp start them and stop them after noting the information
about whether it working properly or not. If not then maintenance is require
for the machine.
• In Auto mode machine Automatically select each and every motor
,drive,sensor,valve and lamp start them and stop them to note the information
about whether it work properly or not. If maintenance is require then go to
maintenance mode of machine.
• We here replace microcomputer system and NOM3 module from the Control
panel of the TD02 with the B&R PLC and program it to work same as
microcomputer system and NOM3 module to save cost of up to 1.25 lakh. Rs.