Design and Optimization of PLC Based Automatic Roving Machine Flyer Speed Control Using VFD

Most commercially used large scale industries, such as spinning, cement, sugar, and food, are now introducing the next step of textile machines control for maximum production due to reduced doffing time, efficiency, energy savings, and human error reduction. Industrial automation technologies such as a Programmable Logic Controller (PLC), a Human Machine Interface (HMI), and a Variable Frequency Drive (VFD) are used to effectively monitor and control the textile industry. The linear density of carding sliver is decreased by drafting rollers in a roving machine or speed frame, and the resultant product is considered roving. The delta PLC and drives are considered in this research to manage the flyer speed and drafting time of a roving machine. Different roving hanks and counts PLC control the flyer speed, twist, gear motor, bobbin rail speed, and direction. Traditional roving machines have been modified to require the use of human power at all speeds and hanks to change the gear setting and pulley. Sometimes, humans make errors in gear setting, so the roving strength changes and produces low-quality yarn. To avoid this problem, PLC and drive control programs are used. The delta PLC control reduces the power consumption of different motors by up to 30%. A precise machine control system for a convenient, quality-assured, and roving-strengthened process. Modbus-485 communication is used to establish an easy way to transfer data values between the controller and drives.