Design and Development of Industrial Embedded Systems

Abstract

Automation has long been used as a technique to reduce manpower and improve efficiency in various industries. In the textile sector, the use of microcontroller-based systems has revolutionized production operations, with advanced versions of Loom Data Monitoring, such as Automatic Power Loom machines and Wireless Loom Data Machines, significantly enhancing automation capabilities. This thesis presents the design and implementation of an Embedded System for Loom Data Monitoring and automation, aiming to streamline textile manufacturing processes. The developed system enables real-time monitoring of the number of clothes produced by the Loom, providing insights into productivity over different time intervals. This data is made accessible through both an LCD and a web server in a Remote Monitoring System, ensuring convenient access to crucial production information. The system incorporates a timer, programmed to count external inputs from a Photoelectric Proximity Sensor, accurately tracking the production output. Furthermore, the system effectively measures yarn stoppages in both warps and wefts, allowing for the identification and mitigation of potential weaving issues on modern-day looms. In addition to textile manufacturing, this thesis explores the application of automation in the consist of Quality. Specifically, it describes a Flat Dripper Inspection system that utilizes computer vision technology to replace manual inspection processes. The system used RS-232 communication, a sensor for camera triggering, and a Human-Machine Interface (HMI) system. The HMI system integrates electronic components with software, mimicking human functions and enabling efficient control and monitoring of the inspection process. Utilizing Nimax software, the system makes informed decisions regarding the acceptance or rejection of Flat Dripper based on image analysis, facilitated by a camera mounted on a conveyor belt. The primary objective of the Flat Dripper Inspection system is to identify defects in objects, replacing complex filtering techniques with a simple yet effective approach. By using a camera as the "eye" of the system, automation improves inspection accuracy, precision, and speed. This Exploration underscores the continuous evolution of technology from manual to mechanical, and from mechanical to automatic, with Human-Machine Interface (HMI) applications emerging as promising products of the future.