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Automatic Thread Winding Machine using Embedded System

Article · March 2017

DOI: 10.22214/ijraset.2017.3132

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 5 III March 2017

http://doi.org/10.22214/ijraset.2017.3132
www.ijraset.com Volume 5 Issue III, March 2017
IC Value: 45.98 ISSN: 2321-9653
International Journal for Research in Applied Science & Engineering
Technology (IJRASET)
Automatic Thread Winding Machine using
Embedded System
Dr. L. Jubair Ahmed 1, Leela Priyadharshini. D2, Malar Jothi. S3, Nithya Devi. P4, Prabhavathi. V5
1
Associate Professor, 2,3,4,5Students, Department of Electronics and Communication Engineering
Sri Eshwar College of Engineering, Tamil Nadu, India.

Abstract-The advances in Automation, has brought innumerous development in various fields especially in textile industries. But
the small scale textile industries are unable to make use of the automatic machines for winding the thread due to complexity and
the high cost. In order to overcome the above scenario, we have proposed this project to wound the thread automatically at low
cost. And also the status of the machine can be monitored and controlled by the sensors. There are three sensors used to detect
the machine is running in proper mode. Piezo sensor is used to detect thread status is in proper mode or cutting mode. Proximity
sensor is used to find the thread length and vibration sensor is used to detect the level of the voltage. Buzzer is used to provide the
indication about the machine status is normal or abnormal. In the simulation process, we use proteus software to simulate the
output and MP Lab is used for programming. ZigBee is used to communicate between user and the processor. The current status
of the thread winder is displayed on the PC.
Keywords: PIC Microcontroller, ZigBee, MP Lab, Proteus, DC Motor.

I. INTRODUCTION
An embedded system performs more functions in a computer design with real-time. Embedded is a part of a complete device which
combines both the hardware and software. A general-purpose computer like personal computer is designed to be flexible and is
more comfortable to meet a wide range of a user's needs. Nowadays, embedded systems control many of the common devices.
Embedded systems are controlled by a main processing core that may be either a microcontroller or a processor. Since the
embedded system is used for specific tasks, design engineers can optimize it, reducing the size and cost of the product, or increasing
the reliability and performance. Some embedded systems are benefited economically, due to mass-production. Embedded system is
suitable for both the portable devices such as digital watches, MP3 players, etc., and for the non-portable devices such as traffic
light, factory controllers, etc. Life is getting simple and easy in all aspects due to automation. Automation is mainly used for
controlling the operating systems and it is applicable in industries, aircraft, etc. The benefit of automation is used to improve the
quality, accuracy and precision. Nowadays, the thread winding machines used are very sophisticated and costly. So, small factories
running loom machine are not able to purchase those costly thread winding machines. So, we thought of upgrading the older thread
winding machines which are still use in small factory. The proposed system is to provide automation in thread winding machines in
small scale industries. In this project, thread is winded automatically without any manpower. Once default mode or user mode has
set, the thread gets started to winding. When it reaches the count of thread value, it automatically stops the motor. When the
machine is in process, the count value of thread is detected by the proximity sensor and the piezo sensor detects the thread cutting.
Nowadays, many industries have one of the major issues like voltage maintenance. In order to reduce the issue, we proposed to use
the vibration sensor which detects the level of the voltage. Here zigbee is used as a communication medium between the machine
and the user. ZigBee and the Personal Computer (PC) can be easily communicated through MAX RS232 which is a serial port
communication.

II. LITERATURE SURVEY

In this table 2.1 shows the different analysis of existing thread winding machine used in large scale industries.

Table2.1: Analysis of the existing thread winding machine

winding machines introduction observation

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©IJRASET: All Rights are Reserved
www.ijraset.com Volume 5 Issue III, March 2017
IC Value: 45.98 ISSN: 2321-9653
International Journal for Research in Applied Science & Engineering
Technology (IJRASET)
manual thread this machine is 1.the thread is
winding machine used for winded
wounding manually.
woollen 2. it takes more
threads, time to complete
especially in the process.
preparing to 3.during this
weave where process the
the yarn is thread gets easily
wound onto a twisted.
bobbin and then
used in a
shuttle.

semi-automatic
thread winding by using this 1. cost of the
machine machine, we machine ranges
can from 50,000-
automatically 80,000.
wind the thread 2. difficult to
automatic thread and partial maintain.
1. the cost is
winding machine the working of very high that it
the machine is ranges in lakhs.
fully automatic 2. replacement of
even the the machine is
packing is very complex.
automatically
done by this
machine. it
displays the
speed of the
motor and the
level of the
voltage.

A. Problem Statement
To propose an automatic thread winding machine which is suitable for small scale industries which includes various features like
1) Consumes time
2) Low Cost
3) Partially it reduces the manpower
4) Measures the accurate length of the thread
5) Update the status of the machine to the user

III. EXPERIMENTAL WORK

In this project, threads are winded automatically and the machine is controlled by three sensors. In Figure 3.1 shows the block
diagram of automatic thread winding machine (transmitter).There are two modes one is default mode which works based on the
predefined value. Second mode is set mode here we set values for each winding using the keypad. When the winding count is set,
corresponding thread will run for specified count. This will be controlled using proximity sensor. The piezo (photo) sensor used to
sense the thread status whether it is normal or broken. And proximity sensor will sense the rpm of the motor and vibration sensor

697
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www.ijraset.com Volume 5 Issue III, March 2017
IC Value: 45.98 ISSN: 2321-9653
International Journal for Research in Applied Science & Engineering
Technology (IJRASET)
senses the motor speed. Buzzer is used to indicate status of the machine. In a receiver side, monitoring section is placed. ZigBee is
connected to PC through MAX232 which is serial communication port and the status of the machine is updated currently in a
personal computer. In Figure 3.2 shows the block diagram of monitoring section (receiver).

Figure 3.1: Block Diagram of Automatic Thread Winding Machine (Transmitter)

Figure 3.2: Block Diagram of Monitoring Section

IV. PROPERTIES OF USED MATERIALS

A. Hardware Used
Microcontroller Pic 16f877a

Figure 4.1: IC PIC16F877A

B. I/O Ports
General purpose I/O pins are the peripherals. PIC microcontroller is allowed to monitor and control the other devices. Many pins are
multiplexed with an alternate function to add flexibility to a device.

C. Port A And Tris A Register

In PIC microcontroller, RA4 pin is used as a Schmitt Trigger input and open drain output. Remaining RA port pins have TTL input
levels and CMOS output drivers. All pins have data direction bits which can configure these pins as output or input. The
corresponding output driver is in high impedance mode when TRISA register bit is set. The contents of the output latch on the
selected pin(s) when a bit is cleared in the TRISA register.

D. Port B And Tris B Register

PORTB is an 8-bit wide bi-directional port. The TRISB is corresponding data direction register. The output driver is in high-
impedance input mode after TRISB is set. When clearing a bit in the TRISB register puts the contents of the output latch on the
selected pin(s). Each pin in PORTB has weak internal pull-up. A single control bit turn on all the pull-ups which is performed by

698
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www.ijraset.com Volume 5 Issue III, March 2017
IC Value: 45.98 ISSN: 2321-9653
International Journal for Research in Applied Science & Engineering
Technology (IJRASET)
clearing bit RBPU. The weak pull-up is turned off automatically when the port pin is configured as an output. The pull-ups on a
Power-on Reset are disabled.

E. Port C And The Tris C Register

PORTC and the TRISC Register is an 8-bit bi-directional port. By using TRISC register, each pin is individually configured as an
input or output. PORTC pins have Schmitt Trigger input buffers. Some peripherals override the TRIS bit to make output, while
other peripherals override the TRIS bit to make an input.

F. PORT D and the TRIS D Register

PORTD is an 8-bit port with Schmitt Trigger input buffers. Each pin is configured as an input or output individually.

G. PORT E and the TRIS E Register

PORTE is an 8-bit port with Schmitt Trigger input buffers. Each pin is configured individually as an input or output. The upper bits
of the TRISE register are used for the Parallel Slave Port control and status bits in some devices with PORTE.

H. DC Motor
A DC motor is designed to run on DC electric power (shown in Figure 4.2). Two examples of pure DC designs are Michael
Faraday's monopolar motor (which is uncommon), and the ball bearing motor, which is (so far) a novelty. By far the most common
DC motor types are the brushed and brushless types, which use internal and external commutation respectively to create an
oscillating AC current from the DC source—so they are not purely DC machines in a strict sense.

Figure 4.2: DC Motor

I. ZigBee
ZigBee is a high-level communication protocols used for wireless networking. It is an unique wireless technology developed for its
low-cost, low-power wireless M2M networks. ZigBee (CC2500) is a low cost true single chip 2.4 GHz transceiver designed for very
low power wireless applications (shown in Figure 4.3). The RF transceiver is combined with configurable baseband modem. ZigBee
devices are required to confirm the Low Rate Wireless Personal Area Network (LR-WPAN) standard. The standard specifies the
lower protocol layers are the physical layer (PHY), and the Media Access Control portion of the data link layer (DLL). The
specification is simple and less expensive than Bluetooth or Wi-Fi. Its transmission limit ranges from 10–100 meters. ZigBee
devices can transmit data over long distances by passing data through mesh network of intermediate devices to reach more distant
ones. It is used in low data rate applications that require long battery life and secure networking.

Figure 4.3: ZigBee

J. Sensor IR Sensor
IR LED emits infrared radiation. Amount of light reflected varies, depends on surface of reflectivity. The reflected light is incident
on reverse biased of IR sensor. Depending on intensity of incident IR radiation, the amount of electron and hole pairs generated. As
the intensity of incident ray varies, voltage across the resistor will also vary accordingly. It is an electronic device that emits to sense

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www.ijraset.com Volume 5 Issue III, March 2017
IC Value: 45.98 ISSN: 2321-9653
International Journal for Research in Applied Science & Engineering
Technology (IJRASET)
the aspects of the surroundings. It measures the heat of an object and detects the motion. All the objects that radiate thermal
radiation in infrared spectrum which are invisible to our eyes which is detected by an infrared sensor. The emitter is an IR LED and
the detector is an IR photodiode which is sensitive to IR light of same wavelength. In Figure 4.4 IR Sensor works as when IR light
falls on the photodiode, the resistances and these output voltages, change in proportion to the magnitude of the IR light received.

Figure 4.4: IR Sensor

K. Vibration Sensor
Vibration sensor usually at any angle switch is ON state, by the vibration or movement, the rollers of the conduction current in the
switch will produce a movement or vibration, causing the current through the disconnect or the rise of the resistance and trigger
circuit. The characteristics of this switch is usually general in the conduction state briefly disconnected resistant to vibration, so it's
high sensitivity settings by IC, customers according to their sensitivity requirements for adjustments. The vibration sensor detects
the shock intensity caused by sudden knocks and continuous vibration. Vibration sensors are easily installed and fixed. Two sensors
is not connected in idle condition. The blue LED indicates communication, online and activation. In Figure 4.5 shows the vibration
sensor.

Figure 4.5 Vibration Sensor

L. Proximity Sensor
In Figure 4.6, Proximity Sensors using high-frequency oscillation to detect ferrous and non-ferrous metal objects and in capacitive
models to detect non-metal objects. Inductive Proximity Sensors detect magnetic loss due to eddy currents generated by an external
magnetic field in a conductive surface. A proximity sensor is a sensor detects the presence of nearby objects without any physical
contact. A proximity sensor emits an electromagnetic field and changes the field. The object being sensed is referred as the
proximity sensor's target. The maximum distance detected is defined nominal range. A proximity sensor measures the current flow
between the electrode and the target provides readouts in units. Proximity sensors can have high reliability and long functional life
due to the absence of mechanical parts and lack of physical contact between the sensor and the sensed object.

Figure 4.6: Proximity Sensor

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IC Value: 45.98 ISSN: 2321-9653
International Journal for Research in Applied Science & Engineering
Technology (IJRASET)
M. Software Used
The following software supports have been taken for the system.
1) MPLab: MPLab IDE refers to integrated development environment. It provides flexibility to develop and debug firmware for
various Microchip devices. It is a Windows-based Integrated Development Environment for the Microchip Technology
Incorporated PIC microcontroller (MCU) and dsPIC digital signal controller (DSC) families.
2) Proteus: Proteus is software for simulation in microprocessor, schematic capture, and PCB design. It is developed by lap center
Electronics.
V. RESULTS AND DISCUSSION
The experimentation is carried out and the following results have been obtained. The status of the machine is updated to the user
through PC. Buzzer is used to alert the user when the machine is in improper condition. In Figure 5.1 represents the output of the
hardware and the simulation output in Figure 5.2.

Table 5.1: Analysis of existing and proposed thread winding machine

EXISTING PROPOSED
THREAD THREAD
FACTORS WINDING WINDING
MACHINE IN MACHINE FOR
SMALL SCALE SMALL SCALE
INDUSTRIES INDUSTRIES

TIME TO WINED 30 15
THE THREAD
(MINUTES)

45 90
PRODUCTION (%)

Figure 5.1 Hardware Output

Figure 5.2 Simulation Output

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www.ijraset.com Volume 5 Issue III, March 2017
IC Value: 45.98 ISSN: 2321-9653
International Journal for Research in Applied Science & Engineering
Technology (IJRASET)
VI. CONCLUSION
In small scale industries, we implement this project to reduce the complexity and cost of the machine. If any fault is identified in the
machine, it can be easily replaced. Measures the accurate length of the thread automatically as given by the user. The status of the
thread will be updated to the user periodically and also alerts the user when the voltage level is increased than required.

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