Computer Applications in Textiles Unit - I

The Computer System

A Computer can be viewed as a system that comprises several units. The term
‘computer system’ refers to the whole of computer hardware, peripherals, and data
communication equipment. It consists of a number of interrelated components that work
together with the aim of converting data into information. Computer Architecture is
defined as the science of selecting and interconnecting hardware components to create
computers that meet functional, performance and cost goals. It is otherwise known as the
manner in which the hardware components of the system are interconnected.

Central processing unit

Memory unit

Control unit Arithmetic /

Logic Unit

Input Unit Output Unit

A computer system essentially has three important components:

1. Central Processing Unit (CPU): This unit performs processing of instructions

and data inside the computer.

2. Input Unit: This component of the computer accepts instructions and data.

3. Output Unit: This unit communicates the results to the user.

1
Computer Applications in Textiles Unit - I

Central Processing Unit (CPU)

The Central Processing Unit or CPU is the ‘administrative’ section of the

computer system. It interprets, coordinates the operations and supervises the instructions.
The CPU contains the circuits that decode and execute instructions. CPU works with data
in discrete form, that is, either 1 or 0. It counts, lists, compares and rearranges the binary
digits of data in accordance with the detailed program instructions stored within its
memory. The results of these operations are translated into characters, numbers and
symbols that can be understood by the user. The circuits necessary to create a CPU for a
personal computer are fabricated on a microprocessor. Some of the basic functions of a
CPU are

 It issues commands to all parts of the computer system.

 It controls the sequence of operations as per the stored instructions.

 It stores data as well as programs.

 It performs the data processing operation and sends the results to the output unit.

The central processing unit itself has three parts

1. Arithmetic Logic Unit (ALU) - This unit performs the arithmetical and logical
operations on the stored numbers. The data is transferred from the memory unit to
the arithmetic logic section, processed and returned to internal storage. Before the
completion of the processing, data may be transferred back and forth between
these two sections, several times. Subsequently, the results are transferred from
internal storage to an output device.

2. Control Unit - This unit checks the correctness of sequence of operations. It

fetches the program instruction from the primary storage unit, interprets them, and
ensures correct execution of the program. It also controls the input / output
devices and directs the overall functioning of the other units of the computer.

3. Memory Unit – This unit holds the intermediate results during the course of
calculations and provides the data as and when required. It stores the program
instructions and data on which the processor is currently working. This internal
storage section is also called as primary memory or main memory. The storage
section takes the data from an input device and stores it until the computer is
ready to process it. It also stores processed data and intermediate results. When
the processing is finished, it transfers the final results to an output device.

2
Computer Applications in Textiles Unit - I

Input, Output and Storage Units

A computer system also incorporates input and output devices which are a
communication medium between a human and the computer. An input unit accepts
instruction and data from the user and communicates them to the computer. The basic
task of this unit is to gather the data and convert it into the form that the computer can
understand. Some of the input devices are keyboard, mouse, light pen, and so on.

Just as humans communicate with computers with input devices, the computer
can communicate with human beings with the help of output devices. Like input units,
output units are instruments of interpretation and communication between humans and
computers. These devices take the machine-coded output results from the processor and
convert them into a form that can be used by the people or as a machine input in another
processing cycle. Some of the commonly used output devices are printers, monitor and
plotters.

The three units of CPU and the input/ output devices form the five important
components of a computer system. In addition to these parts, a computer also employs
secondary storage devices which are extensively used for storing data or instructions. The
physical components or materials on which data stored permanently are called storage
units or devices. It supplies the stored information to the other units of computer as and
when required. Some common storage devices are floppy disks, hard disks, and tape
drives.

3
Computer Applications in Textiles Unit - I

PRACTICE

1. Objective type questions

1. Computer architecture is known as the manner in which the

components of the system are interconnected.

(a) Software (c) Central Processing Unit

(b) Hardware (d) Input/output devices

2. is the ‘administrative’ section of the computer sytem.

(a) CPU (c) ALU

(b) Input unit (d) Memory unit

3. The basic task of this unit is to gather the data and convert it into the form that the
computer can understand.

(a) Output unit (c) Control unit

(b) Storage unit (d) Input unit

4. This unit holds the intermediate results during the course of calculations and
provides the data as and when required.

(a) Memory unit (c) Input unit

(b) Output unit (d) Control unit

5. These are instruments of interpretation and communication between humans and

computers.

(a) ALU (c) Input/output units

(b) Control unit (d) Storage unit

2. 2 marks questions

4
Computer Applications in Textiles Unit - I

1. Define Computer architecture.

2. What are the components of a computer system.

3. What are the basic functions of CPU?

4. What does the control unit do in a computer system?

3. Descriptive type questions

1. Explain with a block diagram the components of a computer system and their
functions.

SPREAD SHEET
The instructions fed to the computer in the form of sheet are called as a
spreadsheet.
It requires

 One MB of RAM

 Compatible running in MS – DOS version 3.0

 Hard disk

 Graphics display

It contains 3 types of program

 Spread sheet program

 Graphics program

 Database management system program

One of the most popular spread sheet package is Lotus 123, written in C language.

Specialties of package:

 Multipage spread sheets

 Multiple active work sheets

 Supports operating system

5
Computer Applications in Textiles Unit - I

 Display graphs and data simultaneously

Lotus 123 is a software which has been developed for use a person with no special
knowledge about computer and programming language.

• Spread sheet program:

Spread sheet electronically duplicates on accountance book keepers tool. It is

having a Ledger bag, pencil, eraser, and calculator. Data can be entered through key
board and it displays on monitor The datas once entered on spread sheet can be applied
for variety of calculations.

• Graphics Program:

Graphics program which enables you to create various graphs like bar or line
graph from the information on work sheet.

• DBMS Program:

Using DBMS program, Lotus 123 can instantly retry or reorganize all the
information without consuming time by turning pages or searching through files.

Electronic Spread Sheet

Electronic spread sheet is basically contains a table of rows and coloumns. It has
enhanced flexibility, speed and accuracy.

Name of some of the package

Old Visicak, supercal

New Lotus 123 and Excel 4.

It contains a 256 rows and 8192 colums.

First 26 columns A to Z

Next 26 columns AA to AZ

Next 26 columns BA to BZ

Application:

• Accounting

• Banking

6
Computer Applications in Textiles Unit - I

• Finance and Economics

• Marketing

• Personal Administration

• Retail Merchandising

• Statistics

Working with electronic spread sheet changing the content of the cell

 User moves the cursor around the electronic spread sheet changing the value of
current cell.

 While typing a formula on the cell, it will be displayed on the top of the screen.

 To change the content of the cell, the cursor can be moved to the cell and the new
content can be entered. The old content is lost and the new value is entered.

 Any cell value that depends on the value of the changed cells is recalculated.

Editing of Spread sheet

 After saving the current content on the disc, the spread sheet can be recalled at
any time later.

 User can erase the content of a single cell or of entire rectangular blocks of the
cell.

 They can automatically adjust the formula from one cell to another cell.

WORD PROCESSOR

Word Processing is a computer term for typing and editing any kind of letters and
memos, articles , reports etc,.

Facilities of word processing:

• Document creation, storage and editing

• Automatic page numbering, centuring,underlining,overtyping and reformatting

and right justification.

• Efficient search

• Global search and replace.

7
Computer Applications in Textiles Unit - I

• Spelling change, sorting and graphics

• Calculation and password security

Advantages of Word Processor

 Increase the office efficiency

 Higher quality output

 Improved human resource utilization with better control

 Faster output speed

 Reduction in amount of proof reading required

 The elimination of stationary wastage

Features of word processor

Basic features are

1. Preparation, editing, formatting and printing of letters

2. Automatic form filling

3. Filling and searching of large information stocks.

Advance features are

1. Shared with the large number of terminals

2. Shared resource systems

Application of word processor

I. A unique report

Apart from assisting a typist with the ease of moving through the text, backwards
and forwards, looking for the parts to edit, a word processor enables automatic
headings and footings, page numbering, bold printing and underling facilities etc,.

II. Report work

8
Computer Applications in Textiles Unit - I

The standard documents which are used often with slight portion specifically
written and rest of it common in general. It can be done using word processing in
a minor time.

III. Mailing List

When one need a document or letter which has some part common and some
fields are changed for different documents. This work can be done by designing a
database of having different fields and using the mail merge facility of the word
processor.

Word Processing Programs

Commands to the word Processor

i. Text Storage

ii. Text Display

iii. Text Editing

iv. Insertion

v. Over Typing

vi. Delete

vii. Move

viii. Copy and Inserts

ix. Formatting and Printing

x. Headers and Footers

xi. Rules and Tabs

xii. Special printing effect

9
Computer Applications in Textiles Unit - I

PRACTICE

1. Objective type questions

1. This program can be used to instantly retry or reorganize all the information
without consuming time by turning pages or searching through files.

(a) Graphics (c) Spread Sheet

(b) DBMS (d) C-program

2. This is a computer term for typing and editing any kind of letters and memos,
articles, reports.

(a)Word processing (c) Signal processing

(b) Data processing (d) Image processing

2. 2 mark questions

1. What are the requirements of spread sheets?

2. What are the specialities of spreadsheets?

3. What is a spread sheet program?

10
Computer Applications in Textiles Unit - I

4. State few applications of spread sheets.

5. What are the advantages of word processor?

6. Write about the basic and advanced features of word processor.

3. Descriptive type questions

1. What are spread sheets? Write about the its features and advantages.

2. Write notes on the applications of word processor.

Database management system (DBMS)

A DBMS is a set of software programs that controls the organization, storage,
management, and retrieval of data in a databaseSystem for quick search and retrieval of
information from a database. The DBMS determines how data are stored and retrieved. It
must address problems such as security, accuracy, consistency among different records,
response time, and memory requirements. These issues are most significant for database
systems on computer networks. Ever-higher processing speeds are required for efficient
database management.

DataBase Management System) Software that controls the organization, storage,

retrieval, security and integrity of data in a database. It accepts requests from the
application and instructs the operating system to transfer the appropriate data. The major
DBMS vendors are Oracle, IBM, Microsoft and Sybase (see Oracle database, DB2, SQL
Server and ASE). MySQL is a very popular open source product (see MySQL).

DBMSs may work with traditional programming languages (COBOL, C, etc.) or

11
Computer Applications in Textiles Unit - I

they may include their own programming language for application development.DBMSs
let information systems be changed more easily as the organization's requirements
change. New categories of data can be added to the database without disruption to the
existing system. Adding a field to a record does not require changing any of the programs
that do not use the data in that new field.

Major Features of a DBMS

Data Security
The DBMS can prevent unauthorized users from viewing or updating the
database. Using passwords, users are allowed access to the entire database or a subset of
it known as a "subschema." For example, in an employee database, some users may be
able to view salaries while others may view only work history and medical data.

Data Integrity
The DBMS can ensure that no more than one user can update the same record at
the same time. It can keep duplicate records out of the database; for example, no two
customers with the same customer number can be entered.

Interactive Query
A DBMS provides a query language and report writer that lets users interactively
interrogate the database. These essential components give users access to all management
information as needed. See query language and report writer.

Interactive Data Entry and Updating

A DBMS typically provides a way to interactively enter and edit data, allowing
you to manage your own files and databases. However, interactive operation does not
leave an audit trail and does not provide the controls necessary in a large organization.
These controls must be programmed into the data entry and update programs of the
application.

This is a common misconception about using a desktop computer DBMS.

Creating lists of data for a user's own record keeping is one thing. However, although
complete information systems can be developed with such software, it cannot be done
without understanding how transactions and files relate to each other in a business system
(see Database Design below). In addition, some type of programming is required,
whether at a graphical drag and drop level or by using traditional languages.

Data Independence
When a DBMS is used, the details of the data structure are not stated in each

12
Computer Applications in Textiles Unit - I

application program. The program asks the DBMS for data by field name; for example, a
coded equivalent of "give me customer name and balance due" would be sent to the
DBMS. Without a DBMS, the programmer must reserve space for the full structure of the
record in the program. Any change in data structure requires changing all application
programs

Database Design

A business information system is made up of subjects (customers, employees,

vendors, etc.) and activities (orders, payments, purchases, etc.). Database design is the
process of organizing this data into related record types. The DBMS that is chosen is the
one that can support the organization's data structure while efficiently processing the
transaction volume.

Organizations may use one kind of DBMS for daily transaction processing and
then move the detail to another DBMS better suited for random inquiries and analysis.

Overall systems design decisions are performed by data administrators and systems
analysts. Detailed database design is performed by database administrators.

CLASSIFICATION OF DBMS

Hierarchical, Network & Relational

Information systems are made up of related files: customers and orders, vendors
and purchases, etc. A key DBMS feature is its ability to manage these relationships.

Hierarchical databases link records like an organization chart. A record type can
be owned by only one owner. In the following example, orders are owned by only one
customer. Hierarchical structures were widely used with early mainframe systems;
however, they are often restrictive in linking real-world structures.

13
Computer Applications in Textiles Unit - I

Organisation

Personnel Finance Technical

Department Department Department

Manager Superior
Manager Superior s Staffs
s Staffs
Managers Technician
Engineers
s

In network databases, a record type can have multiple owners. In the example
below, orders are owned by both customers and products, reflecting their natural
relationship in business.

14
Computer Applications in Textiles Unit - I

College

Computer
English Mathematics Chemistry
Science

Relational databases do not link records together physically, but the design of
the records must provide a common field, such as account number, to allow for matching.
Often, the fields used for matching are indexed in order to speed up the process.

In the following example, customers, orders and products are linked by

comparing data fields and/or indexes when information from more than one record type
is needed. This method is more flexible for ad hoc inquiries. Many hierarchical and
network DBMSs also provide this capability.

Object Databases
Certain information systems may have complex data structures not easily modeled
by traditional data structures. An "object database" can be employed when hierarchical,
network and relational structures are too restrictive. Object databases can easily handle
many-to-many relationships.

15
Computer Applications in Textiles Unit - I

Intelligent Databases

All DBMSs provide some data validation; for example, they can reject invalid
dates or alphabetic data entered into money fields. But most validation is left up to the
application programs.

Intelligent databases provide more validation; for example, table lookups can
reject bad spelling or coding of items. Common algorithms can also be used such as one
that computes sales tax for an order based on zip code.

When validation is left up to each application program, one program could allow
an item to be entered while another program rejects it. Data integrity is better served
when data validation is done in only one place. Mainframe DBMSs were the first to
become intelligent, and all the others followed suit.

16
Computer Applications in Textiles Unit - I

DBMS and OS Interaction

This diagram shows the interaction between the DBMS with other system and application
software running in memory.

17
Computer Applications in Textiles Unit - I

PRACTICE

1. Objective type questions

1. It must address problems such as security, accuracy, consistency among

different records, response time, and memory requirements.

(a) Spread sheets

(b) Word processor

(c) DBMS

(d) MS Office

2. (i) DBMS will not work with traditional programming languages.

(ii) DBMS may include their own programming language for application
development.

(a) (i) is correct and (ii) is incorrect

(b) (i) is incorrect and (ii) is correct

(c) (i) and (ii) are incorrect

(d) (i) and (ii) are correct

3. The DBMS can prevent unauthorized users from viewing or updating the
databse and it is termed as

(a) Data Security

(b) Data Integrity

(c) Data Independence

(d) Database Design

4. This links records like an organization chart.

(a) Network database

(b) Relational database

18
Computer Applications in Textiles Unit - I

(c) Object database

(d) Hierarchical database

5. This type of database can have multiple owners

(a) Network database

(b) Relational database

(c) Object database

(d) Hierarchical database

6. This type of database does not link records together physically but the
design of the records must provide a common field.

(a) Network database

(b) Relational database

(c) Object database

(d) Hierarchical database

7. An can be employed when all the other data structures

are too restrictive.

(a) Network database

(b) Relational database

(c) Object database

(d) Hierarchical database

8. Mainframe DBMS were the first

(a) Intelligent database

(b) Relational database

19
Computer Applications in Textiles Unit - I

(c) Object database

(d) Hierarchical database

2. 2 marks questions

1. What do u mean by DBMS?

2. Name the major features of DBMS.

3. What is Data Integrity?

4. What is Data Security?

5. What do you mean by Interactive Query?

6. What is Data Independence?

7. What is a Database Design?

8. What are the models of DBMS?

3. Descriptive type questions

1. What is a Database Management System? Write in detail about the major

features of DBMS.

2. Write in detail about the Classification of DBMS.

20
Computer Applications in Textiles Unit - I

Microprocessor
It is a silicon chip that contains a CPU. In the world of personal computers, the
term microprocessor and CPU are used interchangeably. At the heart of all personal
computer and most workstations sits a microprocessor. Microprocessors also control the
logic and almost all digital devices from clock radios to fuel-injection systems for
automobiles.

The three basic characteristics that differentiate microprocessors are

• Instruction set: The set of instructions that the microprocessor can execute.

• Bandwidth: The number of bits processed in a single instruction.

• Clock speed: Given in megahertz (MHz), the clock speed determines how many
instructions per second the processor can execute.

In both cases, the higher the value the more powerful the CPU is. For example, a 32-
bit microprocessor that runs at 50MHz is more powerful than a 16-bit microprocessor
that runs at 25MHz. In addition to bandwidth and clock speed, microprocessors are
classified as being either RISC (Reduced Instruction Set Computer) or CISC (Complex
Instruction Set Computer).

21
Computer Applications in Textiles Unit - I

Block Diagram of Micropprocessor:

Primary Memory ROM and

RAM

Input Devices
Output devices
keyboard mouse Monitor
CPU
Scanner Plotters
Microprocessor
Light pen Printer

Joystick Cameras

Secondary Storage
Hard disks
Floppies
CD ROMs DVDs

The above sketch is a block diagram of Microprocessor based Computer. Each

box indicates a functional unit of the computer hardware. Below each box label is a list of
the actual physical entities that can stand for that functions al unit in an actual computer.
The lists are by no means complete but do include the most likely choices. The arrows
show the directions in which information( data and programs) can move among the
different units.

22
Computer Applications in Textiles Unit - I

A modern microprocessor based computer has a CPU capable of 4 billion

operations per second, a minimum of 512 mega bytes – upgradeable to 4 giga bytes – of
primary RAM, 80 to 360 giga bytes of secondary storage( hard disk), a monitor with
resolution up to 1200 by 1024 pixels, with 16 million colours and a key board and a
mouse. A variety of printers are available along with a host of auxillary input, output and
storage devices like scanners, CRROM’s/DVD ROM’s, plotters, cameras, digitisers etc.,

The microprocessors are used for monitoring and controlling of blending and
cleaning and waste removal operations

Blending:

The microprocessor are used in Multimexers or Blenders to monitor and control

the dosage of tufts to each compartment and thus ensure constant delivery to the
opener/cleaner.

Principle of working of microprocessor based modern mixing/ blending machine:

Each chute consists of an independent dosage system. The system consists of a

feed rollers, one is fixed and the other is pressed against the fixed one by a constant force.
The distance between the two rollers is measured 5 times per second on both sides. The
deviations in the cross-sectional area due to fluctuations in material density are sensed
and the input is given to the microprocessor, which processes it and generates an output,
which is given to the Inverter to vary the motor speed and in turn the feed roller speed to
correct the feed rate. Hence the flow of mass per unit time from each chute is maintained
constant.

Cleaning and waste removal:

ABC Control is user – friendly microprocessor based system used to set, monitor
and control the ‘Cleaning Intensity’ and ‘Waste Level’. Based on the desired values for
cleaning intensity (0 – 1) and waste level ( 1 – 10 %) input through the keyboard of
control panel, the ABC control with the help of ‘Varioset Cleaning Field” automatically
changes the beater speed and/or the grid bar angle so that the required level of waste
extraction and cleaning intensity are achieved while the machine is in running condition.

Very easy operation

Two values are entered at the VarioSet: cleaning intensity as a value between 0.0
and 1.0 and relative volume of waste as a value between 1 and 10.These values are
entered on the machine itself or loaded via the ABC Control system. The machine
settings are made automatically, even while the machine is running. The settings are
reproducible. This provides a high level of operating convenience when batch changes
are frequent.

23
Computer Applications in Textiles Unit - I

Carding :

In carding process the Microprocessors and Electronic Control Systems are being
used for monitoring and control of feed rate, sliver count and nep level.

In Trutzschler/ Trumac cards(D K series) the feed table with feed roller forms the
unit. The feed table is provided with the system for scanning of tuft known as
CORRECTAFEED CFD. The feed table is provided sensors, which detect via pedal
levers the variations in the tuft web. The sensors transmit these signals to the electronic
control system for correction of feed roller speed and thus uniform feed is ensured.

The CORRECTACARD CCD serves for a long – term regulation and monitoring
of sliver count. The sliver trumpet on the calendar unit is fitted with a measuring lever,
awhich is linked with a displacement detector(sensor). The measuring lever measures the
thickness of card sliver and converts this information via displacement detector into an
electrical signal, which is transmitted to the control system. On the basis of the difference
between the pre-selected target value and the measured value of the sliver count, the
speed of the feed roller is altered by a controller and thus the sliver count is regulated.
This is known as long-term autolevelling. Thus the modern card has both open – loop and
closed – loop Autolevellers.

On DK 803 card, NEPCONTROL NCT scans the web for neps in the zone
between the strip roll and the squeeze rollers. This constant nep monitoring system
besides giving an estimate of the nep level in the card sliver actuates the grinding
operation in the event of a significant increase nep level from the target value. Hence it
assists in monitoring and control of card slikver quality.

Drawing:

In drawing process the electronic systems, namely AUTOLEVELLERS are used

for monitoring and regulation of sliver count. On most of the Drawframes open – loop
autolevellrs is being used.

An Autoleveller is an electronic device that levels out the mass variations in the
input to produce a uniform output. There are two types of Autolevellers namely ‘open-
loop ‘ and the ‘closed – loop’ Autolevellers.

In open – loop Autolevellers, the measuring sensor is situated in the feed side
before the drafting system. The input mass variations sensed are compared with the set
value and the signal generated is given to the circuit, where it is processed electronically
and the output signal is given to the change the draft in the back zone and thus to level
out the mass variations. The open- loop autoleveller is popularly used on the drawframe,
however it lacks self – monitoring.

24
Computer Applications in Textiles Unit - I

The close - loop autoleveller has the sensing unit situated in the outpuit side to
measure the mass variations of the delivery material. The disadvantage of this system is
that the correction is given to the region following the sensed region in the material.

The scanning rollers scan the throughput mass and compares with the set value.
The signal generated due to difference between actual value and set value if fed to the
electronic circuit, where it is being processed. The output of the autoleveller is given to
the servo motor to change the speed of the middle and/or back drafting rollers, so that the
draft is varied to correct the variations in the input mass. The correction times are in the
range of few milliseconds and the correction length lies in the range of few centimeters.
Thus a uniform sliver is produced by the autoleveller drawframe. Drawframe can be
checked for leveling quite frequently. The accuracy shall lie in the range of ±0.5%.

Spinning

In the ring spinning, Computer system are used for monitoring and controlling of
spinning operation. The popular ones are the Uster RINGDATA system, Premier Ring
Eye 5000, Uster MILLDATA system, Mill I Automatic Data Acquistion System and
EXPERT ERP solution used for process and machine monitoring and control, data
acquisition, planning, information management, etc.,

Ring Eye 5000 is a single spindle production and quality monitoring system. As
ring spinning department is the most capital, labour , power and variation intensive
department in a spinning mill and also as the margins for a spinner are reducing, Ring
Eye is the tool designed to derive the maximum out of the available resources.

Ring Eye helps in achieving this by round – the – clock monitoring of spindle –
wise end breaks and speed, spindles with repeated breaks, spindles with speed deviation
and by providing a history and summary of production and stops. Ring Eye is available
with the software PanorAmilL for customized report formats, numerical/graphical reports
and long term storage and analysis.

The provision of Optispeed 500 with ABC system helps in monitoring and
controlling end breaks through automatic control of spindle speed on ringframe. It
provides optmised speed profile, acquires end breakage information automatically from
Premier Ring I and helps in maintaining uniform workload through constant end
breakage rate.

The Mill Automatic Data Acquisition system helps in automatic data integration
from laboratoty tersters, preparatory and spinning machines and automatic winders
enabling generation of consolidated quality report in a single sheet, quality and
productivity comparisons between machines, material type, etc. It also enables Lot wise

25
Computer Applications in Textiles Unit - I

Quality Consolidation, Tracking of Quality Deviations to its source, Data export facility,
Effective manpower utilisation, and Integration with a wider MIS/ERP system.

EXPERT ERP Solution represents a specialized ERP solution for Spinning Mills.
It helps in optimum raw material selection methodology to ensure yarn quality
consistency. It has a unique identification system for lot tracking through the entire
spinning process. It helps in intergration to automatic data acquisition system from the
production machinery. It represents a closed loop quality control system with provision to
plan, inspect and control quality at every stage. It enables integration of production and
quality data for critical component replacement. It contains the spinning process
knowledge inbuilt in all technical functions. It has got various modules, like Raw
Material Managaement, Production planning, Production, Quality Management,
Maintenance and Utilities, Materials Management, Sales, Finance, Payroll and Human
Resources.

Application of Computers in Yarn Testing

Computers find extensive applications in testing and quality control of yarns.

Measuring head

Signal Recorder/Prin
Processor ter

Display Unit

Yarn Computer System

The figure shown gives a schematic view of the Evenness Tester with computer
system for measurement of yarn unevenness, imperfections and hairiness.

The signal obtained from the measuring head is processed and the application software
with calculator performs the following functions

1. Calculation of various yarn parameters like U%, CV%, CV1m, CV3m, CV10m,
imperfections per kilometer and the hairiness index.

26
Computer Applications in Textiles Unit - I

2. Display of results on the screen

3. Display of results in the form of diagram, spectrogram, VL curves etc.,

4. Recording, storing and retrieving of results.

PRACTICE

1. Objective type questions

1. The set of instructions that the microprocessor can execute

(a) Bandwidth

(b) Instruction set

(c) Clock speed

2. This determines how many instructions per second the processor can execute

(a) Bandwidth

(b) Instruction set

(c) Clock speed

3. ABC Control is user – friendly microprocessor based system used to set,

monitor and control the ‘ tuft size’.

(a) The above statement is correct

(b) The above statement is incorrect.

4. In carding process the microprocessors are used for monitoring and control of

(a) Feed rate, Sliver count and nep level

(b) Cleaning intensity

(c) Waste level

(d) Tuft size

5. The feed table is provided with the system for scanning of tuft known as

(a) CORRECTACARD CCD

27
Computer Applications in Textiles Unit - I

(b) CORRECTAFEED CFD

(c) NEPCONTROL NCT

6. Autolevellers are used for monitoring and regulation of sliver count in

(a) Carding process

(b) Blowroom process

(c) Drawing process

(d) Roving process

7. The measuring sensor is situated in the feed side before the drafting system.

(a) Open- loop autolevellers

(b) Closed – loop autolevellers

8. The sensing unit is situated in the output side to measure the mass variations of
the delivery material.

(a) Open- loop autolevellers

(b) Closed – loop autolevellers

9. The accuracy of the autolevellers shall lie in the range of

(a) ±0.5%

(b) ±0.1%

(c) ±0.4%

(d) ±0.9%

10. This is the tool designed to derive the maximum out of the available resources.

(a) Sliver Eye

(b) Loom Eye

(c) Ring Eye

28
Computer Applications in Textiles Unit - I

11. Results are displayed in the form of diagram, spectrogram, VL cures in

(a) Evenness Tester

(b) Ring Eye

(c) Sliver Eye

2. 2 marks questions

1. What is a microprocessor?

2. What are the basic characteristics of microprocessor?

3. What is the use of microprocessor in blending and cleaning?

4. What is the use of CORRECTCARD CCD and NEPCONTROL NCT?

5. What are the types of autolevellers in drawing and write about them.

6. What does a Ring Eye system do in spinning?

3. Descriptive type questions

1. Write about the applications of microprocessor in textiles.

29
Computer Applications in Textiles Unit - I

SENSORS AND ACTUATORS

Computer exists in a world of digital pulses very different from the analogue
world of everyday matters that surrounds us. As long as the two worlds exist apart –
computers accepting data through keyboard and mouse and outputting results through
monitor and printer – no conflict arises, but when we wish to use computers to monitor
and control processes occurring in the real world we find that the two worlds interface
extremely poorly. Special hardware, special circuits and special programs are needed to
permit computers to make measurements of analogue quantities and even more programs,
circuits and hardware is necessary to permit then to control analogue processes.

Sensors are sometimes called as transducers, are devices that can take a physical
quantity and convert it to an electrical signal whose voltage is proportional to the value
of the parameter being converted .Parameters for which this can be done are called
transduceable parameters. Sensors exist that are capable of the conversion of various
parameters like force, strain, displacement, temperature etc.,Unfortunately the computers
cannot understand an analogue voltage. So the analogue voltage has to be converted to a
digital signal – a set of pulses – which is the dynamic equivalent of the pattern of zero’s
and one’s stored in the computer’s RAM and which is all the computers really can
understand

Strain gauge

The strain gauge is a sensor that converts deformation under load to an electric
signal.

The resistance of a section of conductor is given by the formula R = ρ L 0 / A0,

where ρ is the specific resistivity. L0 is the length and A0 is the area of cross section. Now
when the conductor is compressed axially it will deform as shown below.

30
Computer Applications in Textiles Unit - I

When the conductor is strained in this manner, the value of L will decrease and
that of A will increase as shown in the sketch above. The net effect will be to decrease
the resistance of the conductor.Similarly when the conductor is stretched axially it will
deform as shown below,

same section under tensile deformation

Deformation exaggerated for clarity

Here L will increase and A will decrease so that the resistance of the conductor
will increase. A strain guage consists of a stiff pad to which a long length of wire is
fixed, folded back and forth as shown below.

Schematic of a strain gauge

No. of lengths of wire reduced for clarity
The bonding pad is stuck to the object to be strained so that it and the wire fixed
to it shares any deformation that might occur. Factors like temperature can also change
the resistance of a conductor. Ideally strain gauges should be used in pairs or in bridge
circuits so that such effects can be compensated. The constant of conversion from strain
to voltage is known as the “gauge Factor”.

31
Computer Applications in Textiles Unit - I

Resistance – Type Transducers

Included in this category of transducers are strain gauges and moving

contacts(slide wire variable resistors). A strain gauge measures the external
force( pressure) applied to a fine wire. The fine wire is usually arranged in the form of a
grid. The pressure change causes a resistance change due to the distortion of the wire.
The value of the pressure can be found by measuring the change in resistance of the wire
grid. The pressure to resistance relationship is

R= K L/ A

Where

R= Resistance of the wire grid in ohms.

K= Resistivity constant for the particular type of wire grid.

L = Length of the wire

A= Cross sectional area of wire grid.

Strain Gauge Pressure Transducer

Strain Guage

As the wire grid is distorted by elastic deformation, its length is increased, and its
cross-sectional area decreases. These changes cause an increase in the resistance of the
wire of the strain gauge. This change in resistance is used as the variable resistance in a
bridge circuit that provides an electrical signal for indication of pressure.

32
Computer Applications in Textiles Unit - I

Strain gauge Pressure Transducer

Strain Gauge Used in a Bridge Circuit

An increase in pressure at the inlet of the bellows caused the bellows to expand.
The expansion of the bellows moves a flexible beam to which a strain gauge has been
attached. The movement of the beam causes the resistance of the strain gauge to change.

The temperature compensating gauge compensates for the heat produced by current
flowing through the fine wire of the strain gauge.

Strain Gauge Used in a Bridge Circuit

Strain gauges which are nothing more than resistors are used with bridge circuits.
Alternating current is provided by an exciter that is used in place of a battery to eliminate
the need for a galvanometer. When a change in resistance in the strain gauge causes an
unbalanced condition, an error signal enters the amplifier and actuates the balancing
motor. The balancing motor moves the slider along the slide wire, restoring the bridge to
a balanced condition. The slider’s position is noted on a scale marked in units of pressure.

33
Computer Applications in Textiles Unit - I

Resistance – Type Transducers

Other resistance-type transducers combine a bellows or a bourdon tube with a

variable resistor. As pressure changes, the bellows will either expand or contract. This
expansion and contraction caused the attached slider to move along the slide wire,
increasing or decreasing the resistance and thereby indicating an increase or decrease in
pressure.

Bellows Resistance Transducer

Inductance – Type Transducers

The inductance – type transducer consists of three parts: a coil, a movable

magnetic core and a pressure sensing element. The element is attached to the core and as
pressure varies, the element causes the core to move inside the coil. An AC voltage is
applied to the coil and as the core moves, the inductance of the coil changes. The current
through the coil will increase as the inductance decreases. For increased sensitivity, the
coil can be separated into two coils by utilizing a centre tap,. As the core moves within
the coils, the inductance of one coil will increase, while the other will increase.

34
Computer Applications in Textiles Unit - I

Inductance – Type Pressure Transducer

Differential Transformer

Differential Transformer

Another type of inductance transducer utilizes two coils wound on a single tube and is
commonly referred to as Differential Transformer. The primary coil is wound around the
centre of the tube. The secondary coil is divided with one half wound around each end of
the tube. Each end is wound in the opposite direction which caused the voltages induced
to oppose one another. A core, positioned by a pressure element is movable within the
tube. When the core is in the lower position, the lower half of the secondary coil provides
the output.

35
Computer Applications in Textiles Unit - I

Photoelectric sensors

In general, photoelectric sensors are divided into two categories

• Reflective type
• Through beam type

In Relfective type photoelectric sensor, the light beam emitted by the light emitting
element is reflected by the target/object and then it is received by the light receiving
element. The light emitter and the light sensor are fixed in the same housing. Absent of
the target reduces the intensity of light reaching the receiving element and the presence of
the target increases the intensity of light reaching the receiving element.

In the case of Through beam type photoelectric sensor, the light emitter and the light
sensor are separated out. If the target intercepts the beam it creates a reduction in
intensity of light or total absence of light falling on the received. Both types are widely
used in industrial applications.

(a) Reflective Type ( b) Through beam Type measurement

The detecting range of a photoelectric sensor is defined as the maximum distance

from the transmitter to the receiver that permits the receiver to receive a stable light beam
emitted from the transmitter for Through beam type or reflected from the reflector in the
case of Reflective type. The speed of operation of the photoelectric sensor is normally
specified in the form of response time. The minimum period of time required for the
sensor absence of a light beam and output of OFF signal.

Applications

• Detection of slots and holes

• Detection of position of rotary switches and cams
• Confirmation of proper gripping action of transfer press or robotic arm
• Detection of small parts like E- ring
• Detection of component placement (R-L-C components and transistors)

36
Computer Applications in Textiles Unit - I

• In Textile industries Photoelectric Sensors are used in Blow Room machines,

Yarn Clearer and Loom.

High Precision Laser Beam Photoelectric sensors

Whenever a target is introduced between the Laser beam source and Light sensing
element, the output voltage decreases proportionally with the area of the target.

Measurement setup using Laser beam

The beam width varies from 1mm to 30mm. The minimum detectable object size
is as low as 0.05mm diameter.

Proximity sensors (Electromagnetic induction type proximity sensor)

A high frequency oscillator used to create a high frequency magnetic field. If

ferrous material is brought near the magnetic field the impedance of the sensing coil
increases and the oscillation is suppressed. A reflector circuit is used to detect this
condition.

Proximity sensors are divided into two categories

• Self contained sensors

• Separate amplifiers sensors
In the self contained sensors, the sensor head contains the sensing coil and associated
circuit to provide the DC output voltage. It can be used for short distances upto a
maximum of 30mm.

In the case of separate amplifier sensors the sensor head contains only the sensing
head and the processing circuit is always connected to the head through a coaxial cable.
By adding a high gain amplifier the detecting range can be increased to a maximum of
100 mm. They are called as long distance proximity sensors.

37
Computer Applications in Textiles Unit - I

Block diagram of Proximity Sensor

Advantages

1. Non-contact detection
2. Long detecting range(10m)
3. High speed detection
4. Detection of targets of wide range of materials
5. Highly reliable
6. Quick and automatic calibration

Applications

• Ring frames
• Loom
• Embroidery unit
• Fabric processing unit

Displacement Sensors

The principle of operation of inductive gauging sensor is more or less same as that
of Electromagnetic induction type proximity sensor. As the target approaches the sensor,
the eddy current increases thereby reducing the oscillation amplitude. The oscillating
amplitude is converted into change in DC voltage. After processing the output voltage
with a linear circuit, the output is made to increase linearly with displacement.

38
Computer Applications in Textiles Unit - I

Displacement measurement using inductive gauging sensor

Laser beam Displacement Sensors

The semiconductor laser displacement sensor consist of a light emitting element

and a position sensitive detector. The laser beam is made to fall on the target. The
diffused reflection component is then focused on the position of the beam falling on the
position sensitive detector. The displacement is then determined by detecting the
movement of the beam.

Displacement measurement using Laser beam

Vision system for Position Detection

The target or object pattern is focused on the image pick up element of the
camera. The pattern is stored as an electric charge proportional to the brightness of each
part of the image. This data is sequentially read from one edge to the other edge and then
converted into an image signal./Both interlaced and non-interlaced scanning methods are

39
Computer Applications in Textiles Unit - I

used in vision sustems with the image signal along with the vertical and horizontal
synchronisisng signals fed to the image processing system for feature extraction in binary
digital conversion the areas brighter than the threshold is called as black. For finding
area, position and pattern matching binary digital conversion is widely used. In gray level
processing method, the brightness level of each pixel is represented with 8 bits.This is a
more versatile system and is used for high accuracy measurement.

Block diagram of Vision system

There are number of special functions incorporated in most of the vision systems.
The image captured by the camera is normally divided into 256 levels of gray. By setting
a threshold level the image can be converted into black and white regions. The feature
will be of immense use in object identification. It is possible to capture the image at a
particular instant by means of external triggering facility. Input from an external;
photoelectric or proximity sensor cab neb made to trigger the vision system to capture the
image at rising edge of the trigger input. In certain vision systems match and mismatch
detection modes are also incorporated. In the match detection mode the system count the
number of matched pixels and in mismatched mode the system counts the mismatched
pixels by comparing the gray – processed image with the reference image. This facility
can be used for pattern recognition.

Applications

• Fabric inspection
• Cord web inspection
• Tack and Loom and Wet Processing Industry.

LVDT (Linear Variable Differential Transformer)

A device which provides accurate position indication throughout the range of

value of control rod indication throughout the range of valve or control rod travel is a
linear variable differential transformer. LVDT measures linear displacement continuously
using magnetic coupling. No physical connection to the extension is required.

40
Computer Applications in Textiles Unit - I

Linear Variable Differential Transformer

The extension valve shaft or control rod is made of a metal suitable for acting as
the movable core of a transformer. Moving the extension between the primary and
secondary windings of a transformer caused the inductance between the two windings to
vary, thereby varying the output voltage proportional to the position of the valve or
control rod extension.

41
Computer Applications in Textiles Unit - I

PRACTICE

1. Objective type questions

1. Sensor that converts deformation under load to an electric signal

(a) Differential transformer

(b) Strain gauge sensor

(c) LVDT

(d) Photoelectric sensor

2. This compensates for the heat produced by current flowing through the fine wire
of the strain gauge.

(a) Temperature compensating gauge

(b) Resistor

(c) Capacitor

3. This type of sensors consists of a coil, a movable magnetic core and a pressure
sensing element.

(a) Resistance –Type Transducers

(b) Inductance – Type Transducers

(c) Strain Gauge Pressure Transducers

4. The light beam emitted by the light emitting element is reflected by the target and
then it is received by the light receiving element.

(a) Beam type

(b) Reflective type

(c) Refractive type

42
Computer Applications in Textiles Unit - I

5. The minimum detectable object size is as low as

(a) 0.03 mm diameter

(b) 0.02 mm diameter

(c) 0.07 mm diameter

(d) 0.05 mm diameter

6. In this type of sensors , a high frequency oscillator is used to create a high

frequency magnetic field.

(a) Proximity sensors

(b) High precision laser beam type sensors

(c) Displacement sensors

7. This type of sensors consists of a light emitting element and a position sensitive
detector.

(a) Proximity sensors

(b) High precision laser beam type sensors

(c) Laser Beam Displacement sensors

2. 2 marks questions

1. What is a sensor? What are the different types of sensors?

2. Write about resistance type sensors.

3. What is LVDT?

4. What is a Differential Transformer?

5. What are photoelectric sensors?

6. Write about Vision type sensors?

7. Write the applications of Photoelectric sensors.

3. Descriptive type questions

1. What is the need for sensors? Write about the different types of Strain gauge
sensors used in textile industy.

43
Computer Applications in Textiles Unit - I

2. Write short notes on

(i) Displacement sensors

(ii) Photoelectric sensors

44