Intended for Measurement Mainly in Textile Industry Pavel Klouček, Václav Čejka, Jan Brandt CENTER OF ENGINEERING RESEARCH AND DEVELOPMENT LIBEREC, CZECH REPUBLIC
The first generation of measuring device WAWEON was developed in VUTS in 2001 Two input channels for strain gauge sensors Input for external trigger Time or pseudo angular measurement Based on FPGA Connected to PC via LPT/USB Sold worldwide as service device and for R&D 2
The precise semiconductor strain gauge sensors for dynamic measurement of yarn and warp tension force Yarn (weft) tension force two different ranges two different packages natural frequency 7kHz Warp tension force unilateral/bilateral version sensor with two ranges natural frequency 1200 Hz 3
Why a new development? Request from customers for possibility of connection some other sensor with voltage or current signal Measurement with real angular base precise analysis of behavior during one period, possibility of measurement in conditions with variable angular velocity Increasing a number of measured channels and possibility of synchronization New possibilities of a wireless communication Usage of the other mobile platforms (tablets, smart phones) Usage of this system as a controller and measuring device at the same time Add some new features (e.g. measurement of the yarn velocity) 4
Hardware was based on controller NI sbrio-9651 It uses technology System-on-Module Low power consumption Wide connectivity Ethernet Serial lines USB CAN bus Contains FPGA Newly designed PCB with all input and output circuits Fast A/D converters Up to four input channels External trigger and timebase inputs 5
Input and output channels Two inputs for strain gauge sensors current or voltage supply for semiconductor or foil strain gauges Two voltage inputs with range up to ±10V Two current inputs with range 4 to 20 ma Two IEPE (Integrated Electronic Piezoelectric) inputs for e.g. accelerometers One encoder input with TTL logic ( three channels A, B, Z) External timebase input External trigger input External timebase output Ethernet, USB and Wi-Fi communication in basic model CAN bus or RS485 for special applications 6
Software for the controller Programmed in Lab-View and divided into two basic parts 1) Code for the FPGA Data acquisition from A/D converters Data distribution to the controller Synchronization of different input channels 2) Real time operating system for controller Communication with user s control device Saving of actual configuration Data acquisition from the FPGA Whole code is a modular system easy changes 7
Software for the control device Setting the measurement parameters, sensors, sampling frequency Visualization, basic evaluation and comparison with saved data Intended to be used mainly in mobile devices with different OS Identical code packages can be used in more platforms Software was programmed in Delphi SW is now able to work in: Windows (standard PC or notebook) Android ios Usage for Mac OS is in preparation 8
Prepared basic measuring modes 1. Non-periodical measurement Standard time-based measurement with chosen sampling frequency up to 100kHz 2. Trends statistics Suitable for long-term measurements (e.g. stability of brake, bobbin diameter influence) Measured part of signal with high sampling frequency is represent as mean value, maximal and minimal value and standard deviation 3. Periodical measurement Data sampled in angular domain (pseudo or real one) for rotating or periodical machines 4. Periodical statistics Periodical angular measurement with the statistics results (MNV, Max, Min, RMS) for chosen number of periods 5. Adjustment mode Periodical measurement focused on setting of machines trend of changes is visualized 9
Examples of practical use Warp tension measurement Two Jacquard looms produced 315cm wide fabric from two warp rollers The first one was air-jet loom, the second one was rapier loom One unilateral warp sensor in periodical statistics mode, 220 threads for 50mm of warp was measured 10
Examples of practical use Warp tension measurement Air-jet Rapier 11
Examples of practical use Weft tension and velocity measurement Yarn tension sensor A prototype of novel sensor for weft velocity developed by P. Bandara and F. Junaid (University of Leeds) Measurement of a glass weft on the air-jet loom VUTS Cam-El 12
Examples of practical use Upper thread tension in sewing machines A level of force stability during sewing can influence visual result and also firmness of the seam A lot of parameters can affect the tension force (thickness of sewn material, velocity of sewing, type of thread, type of needle etc.) Yarn tension sensor in an industrial package mounted to the machine Both time and periodical measurement were done Car seat BMW backrest cover sewing 13
Examples of practical use Upper thread tension in sewing machines Different fineness of the upper thread Different speed of the sewing machine 14
Conclusion The second generation of the WAWEON analyzer was developed and prototype board was built Number of input channels was increased to four Different types of input signal (strain gauge, voltage, current, IEPE, encoder) The real angular base measurement was added User friendly software with prepared measuring modes for textile machines Wireless communication with different platforms of mobile devices WAWEON AD can serve as controller and measuring device at the same time development of special measuring devices Different levels of usage service, development, research 15
Acknowledgement This reserach and development was done with support of Clutex Cluster of Technical Textiles, Liberec, Czech Republic and financed from European Regional Development Fund. Visit our booth H8-A139 THANK FOR YOUR ATTENTION 16