Automated Control and Monitoring of Knitting · PDF fileAutomated Control and Monitoring of...

International Journal of Engineering & Technology Sciences

Volume 03, Issue 01, Pages 22-31, 2015 ISSN: 2289-4152

Automated Control and Monitoring of Knitting Machine

Payam Fathollahi Rad a,*, Bashir Fotouhi b

a Department of Engineering, Ahar Branch, Islamic Azad University, Ahar, Iran. b Department of Engineering, Sanandaj Branch, Islamic Azad University, Sanandaj, Iran.

* Corresponding author. Tel.: +98-21-66916840;

E-mail address: [email protected]

A b s t r a c t

Keywords:

Knitting,

Dobby,

Automation,

AVRxmega,

Servo,

Pattern designing.

In the current article, a new practical method was implemented for control and

monitoring of purely-mechanical dobby knitting machines. A conventional machine

cannot change the fabrication procedure for a pattern change. This machine has a main

motor and four servo motors and its process contains three steps: programming, controlling

and monitoring. The new customized programming language carried out in LabVIEW; a

powerful low-noise microprocessor was used to control the loop and LabVIEW was used

for the monitoring process. The optimized interface protocol exchanges data between

LabVIEW and the control board was a novel high-speed and low-noise protocol with

check sum. Programming, color design, shape design, monitoring and fabrication speed

were performed easier, faster and safer.

Accepted: 26 January2015 © Academic Research Online Publisher. All rights reserved.

1. Introduction

The focus of this paper was on the control of four-

axis dobby knitting machines. These machines are

considered as an important part of the industrial

systems which must texture clothing for people. A

knitting machine may be flat, circular, jacquard and

dobby loom [1-4]. The main concentration of this

paper was studying dobby type knitting machines.

Dobby loom first appeared around 1840, which was

almost 40 years after the invention of Jacquard

device by Joseph Marie invented; this device could

be mounted atop a floor loom to lift individual

heddles and warp threads [1, 2]. Both jacquard and

dobby looms are floor looms in which a device

called heddle is used to attach every warp thread on

the loom to a single shaft. Each shaft controls a set

of threads and the loom including several shafts

gives a huge variety of sheds through which a shuttle

containing weft thread can be thrown. A manual

dobby has a chain of bars or lags with inserted pegs

for selecting the movement of the shaft. In

conventional all mechanical dobby machines, all

shafts are controlled by a treadle. The ability for

handling much longer sequences in the pattern is

considered an important advantage for dobby

machine. A weaver which is working on a loom

must remember the entire sequence of treadling

which makes up the pattern and must always keep

track of their places in the sequence. Getting lost or

Payam Fathollahi Rad & Bashir Fotouhi / International Journal of Engineering and Technology Science (IJETS) 3 (1): 22-31, 2015

23 | P a g e

making a mistake can ruin the cloth that is being

woven. Dobby looms are capable of expanding

weaver’s capabilities and removing some of the

tedious works involved in designing and production.

Many newer cloth design techniques, such as

network drafting, only can reach their full potential

on a dobby loom.

Knitting machines could be traced back to 1589

when Rev.Lee invented his knitting frame; this

frame was programmed using paper type. During

recent 40 years, there have been rapid developments

with regard to the introduction of electronic, image

processing, fuzzy, adaptive and neural control of

knitting machines [5-10]. “Knitting machines get

8085 controls” is the title of a well-known industrial

system which was developed by Stonefield

Electronics [11]. Some of these control systems are

based on yarn input tension (YIT) which is an

approach for detecting faults and monitoring the

knitting process [12, 13]. Due to its nature, the yarn

input tension constitutes a valuable way for

diagnosing machine functioning [13]. However,

there was a need for both exact fault detection and

real-time process and monitoring knitting procedure

which made the desirable systems more complicated

[14-16]. Making up garments using earlier

computer-controlled machineries using sensors and

intelligent controls was developed by Department of

Mechanical Engineering, Loughborough University

of Technology [10]. Moreover, modelling and

visualization of 2D and 3D shapes of knitwear

through scanning process led to virtual design and

fast prototyping [17, 18]. Big changes occurred in

the control systems since 2000 when AC servo

brushless motors were introduced in the application

of knitting machines. Due to high speed and

accuracy, servo motors as powerful devices have

been used to precisely place needles in knitting

machines and circular warp knitting machines use

servo motors to place needle in the desired places for

weaving the pattern. This machine uses two servo

motors [19], which require a frequency invertor to

be applied for industrial systems. While using full

potentials of a servo system, all calculations,

communications and control loops need to be

entrusted to a powerful device such as DSP [20, 21].

Linux architecture control system and GUI have

been applied to computerize flat knitting machines.

This system uses a powerful ARM microprocessor

(AT91SAM9261) for controlling the loop [22].

Some others similarly control a jacquard knitting

machine while using the specifications of [22] to the

system [23]. CAD/CAM system recommends image

processing techniques to create of specified knitting

structures and products [23, 24]. Transformation of

grey level images to binary images and path tracing

are the methods used for cotton knitting industry

automation [23]. Wireless monitoring system and

sketch pad for circular knitting machine and

conceptual design of 2D garment patterns are the

boundaries of knitting monitoring technology [25].

Combination of all servo mechanism and signal

processing systems with a powerful monitoring

system has not been introduced yet. Making the

desirable pattern and monitoring the system’s faults,

simple GUI, simple patterning and some other issues

are still open problems in the area of knitting

machines. Therewith, these studies do not include

issues on dobby loom machines.

Accordingly, the first aim of this paper was to

present a set of control and monitoring system based

on the conventional (purely mechanical) four-axis

dobby knitting machine. Moreover, a new simple

programming rules for pattern fabrication and real-

time monitoring were two aspects of open problems

in this kind of machines. The proposed automated

machine used both software and hardware

techniques to overcome basic problems of


24 | P a g e

automation. Real-time monitoring of fabrication

process was able to find program faults, errors and

wrong woven areas. The operator did not require

calling the company for the change of desired

pattern. Consequently, simplicity of pattern

programming would make the machine more user-

friendly. Pattern change could be rapidly performed.

Also, the operator could save different patterns in

memory and call them back to the weaving process.

The machine was cost-effective, even though many

servo systems, drives, computer, software and

control board were used. Section two describes

mechanical/electrical parts in the dobby loom. In

Section three, control system including software,

control board, communication protocol and pattern

programming are described.

2. Knitting Machine

The proposed machine was of dobby type and

included four axis. In this machine, two moving

combs, as shown in Figure 1 performed task of

weaving procedure. Different color yarns crossed

into the orifices of horizontal comb “A” and then

needles of hooks of vertical comb “B”. This

operation caused the pattern fabricated, which was

the manner to change position of combs for making

the pattern. Each cycle of comb “B” was equal to a

row of the fabricated pattern. The changing position

of the comb hook “A” shifted the input color to the

equivalent hook in comb “B” and results in different

patterns and colors. Each pair of the combs “A” and

“B” is called an axis. The increasing in the number

of axis enhanced the ability for weaving more

complex patterns. Therefore, the displacement step

of each axis, synchronization of combs and roll

speed of yarn input, language of programming and

control system design of closed loop were all

important. Each step of the comb “A” would result

in a shift in color series and any reciprocating motion

of comb “B” would complete one row fabrication of

the pattern. Again, comb “A” would change the

place in the length of one or more steps and the

subsequent motion of comb “B” would occur again.

These procedures were repeated until the pattern

completion. Figure 2 demonstrates a simple

schematic of comb “A” and its actuator for changing

place in predefined steps. Servo motor rotated CW

and CCW in predefined angular steps; this rotation

displaced the comb “A” again by the predefined

steps related to servo motor step and length of

camshaft, which transformed rotation displacement

to a horizontal type. It should be noted that the total

rotation of servo motor must be less than or equal to

70˚ due to mechanical limitations, both software and

hardware appliances have been implemented.

Assuming that L is the length of camshaft, α is angle

of camshaft to the vertical line and D is distance of

comb “A” to the vertical line of servo motor, thus:

raddkN

radd

dLCosdDL

DSin

61086.022173.1

)()(

(1)

Nk

NkCos

NLkdD

,...,2,1,0

)61086.022173.1

(22173.1

)(

(2)

where k is current step, N number of total steps and

dα rotation angle due to each step. Assuming equal

rotation angle for all the steps, results in the point

that displacement of each hook in comb “A” is a

simple function of the number of current step k. In

the proposed machine, N=15 and each step yielded

the change in servo position of about 4.63˚.

Precision of rotation angle was restricted by the

precision of closed loop servo system, which is

about 0.036˚ and more precise than what we need.


25 | P a g e

Fig.1 Horizontal displacement (Comb A) Vertical

displacement (Comb B)

Fig.2 Actuator system of comb “A”

Table. 1: Description of electrical instruments used in the

system

Device Quantity Description

Servo Motor 4 1KW-ASD-

A21021-B

Servo Drive 4 1 KW- ECMA-

F11010AS

AC Motor 1 1.5 KW

Frequency

Inverter

1 1.5 KW-LS-ic5-

SV

Proxy Switch 1 Hall effect

Computer 1 Industrial -

2.4GHz

Software - Labview 2009

Table. 2: Used components of Micro Processor

AVRxmega Description

Clock 32 MHz, Internal

Timer/Counter 7× 16 Bit

USART 5× 115200

DAC 12 Bit, 1 Msps

Used I/O 50

Low Voltage 1.6 V – 3.3 V

EEPROM 128 Kbyte

After all, comb “A” did the job, then comb “B”

should be raised to the top point. All yarns were fed

to hooks of comb “B” and were pulled down while

none of “A” combs change place at this time. Figure

1 is assumed, comb “B” would go up to a place

amidst hooks of comb “A”. If comb “A” changes

place even by one step, hooks of both combs would

knap. It is important to ensure that comb “A” does

not displace while comb “B” moves at the top; both

hardware and software appliances are implemented.

From electrical point of view, this automated

machine must perform the following tasks: an

operator writes the program for a desired pattern, the

operator chooses his/her favorite colors, the system

should compile input pattern and be replayed to the

user if any error exists. The system loads the pattern

to the control board and knitting machine runs to the

end of pattern. Designing a system at a high level of

accuracy which has a user-friendly programming

language is very important. A complete but

simplified schematic of the control system including

four AC servo motors with their own drives, one AC

asynchronized motor with its own frequency

inverter, control board, proxy switch and a PC is

given in Figure 3. To simplify the schematic, yarn

input DC motors were omitted from Figure 3. The

proposed system must be able to properly satisfy

some important features, as listed here: run

continuously and automatically, preserve

mechanical combs from any damage, preserve servo

motors in order not to rotate out of range, simple and

user friendly programming, variable speed control,

position control and monitoring of the servo motors,

monitor speed of the fabrication procedure, monitor

and report the faults, error, status of the machine,

define access level for the users, compile the pattern

and simple language for the pattern to be entered.


26 | P a g e

3. Control System

It may be more understandable to do programming,

controlling and monitoring by explaining each part

individually in detail. Each pattern fabrication

procedure must pass through the following chart in

Figure 4. First step is given in parts 3.1 and 3.4 since

conversion of a desired pattern to a specific code is

done by the software. Indeed, pre-defined rules and

programming language are required also. The

second step would be done by the software too, by

compiling the code wrote by the operator. While

loading the program to the control board, the

hardware gets involved with the process for the first

time. This is step explained in parts 3.1, 3.2 and 3.3

because software, hardware and communication

protocol are all involved. Finally, real-time control

and monitoring of the fabrication procedure shall be

explained for each section in all parts. Control loop

only involves control board, servo drives, frequency

inverter and proxy switch and there is no need for

the software. However, monitoring consists of

software, communication protocol, frequency

inverter, proxy switch and control board.

3.1 Software

As the first part of the above-mentioned system, here

the software is briefly explained. The proposed

software which supposed to be the user and machine

interface is LabVIEW-based, because of

compatibility with industrial and personal

computers, high-speed processing and

communication and having a simple and user-

friendly graphical environment.

3.2 Control Circuit

Since the proposed control system must be

compatible with the industrial environment, it is

necessary to use high-speed and low-noise micro

controllers. Since 2008, as a new processor

specialized for industrial environment is available

Fig. 3: A schematic of the control system

Fig. 4: Control and monitoring general step

Some important features of this processor are used

(as listed in Table 2), but the processor is compatible

with higher frequency, higher sampling rate and

other specifications. As shown in Figure 6, all the

tasks of position control of servo motors, set speed

and feedback speed of main motor, comb

commands, setting and reading servo drive

parameters, executing pattern programmed by the

operator and sending monitoring parameters to the

computer are controlled by the board. The control

board decodes the pattern and calculates all servo

positions for each step. Then, servo drive parameters

are set through serial ports of all the drives and four

serial ports on the board; the protocol is MODBUS

and baud rate is 115200 bps.


27 | P a g e

Any changes in digital inputs or serial port

commands results in one interrupt; i.e. every servo

drive position command, enabling/disabling the

signals, computer or operator command and proxy

switch signal, which cause specific interruption in

system control. It is important to assign one interrupt

loop and subroutine to each action or reaction of the

system. The ability of making hardware-interrupt for

all digital I/O and software-interrupt for all analogue

I/O keeps precise attention on real-time control and

monitoring. All subroutines and control flowchart

are shown in Figure 5. Every specific time steps, the

control system saves all the essential data such as the

number of steps, remaining steps, and current

positions in order to continue the fabrication process

after the fault or disconnection of power supply. It is

worth mentioning that MODBUS communication

only sets initial conditions in servo drives and

reports their faults/alarms. After the drives are

initialized and parameters are set, the position of

servo motors is controlled through seven digital

inputs of the recommended drive. As a result, servo

motor settling time of the position becomes faster

and safer. To obtain lower power consumption, less

speed of the main motor and high weaving speed

also the need for more cams on the shaft of the motor

is indispensable. Accordingly, four cams are placed

with the same intermediate angles on the shaft.

Intermediate angle is 90˚, H is width of cams and D

is width of proxy switch. Here, H is assumed to be

smaller than and closed to D. While each one of the

cams is placed in front of the proxy switch, comb

“A” moves toward the next step. One rotation of

motor shaft leads to four steps of comb “A”. Thus,

fabrication speed increases by a factor of four. The

applied frequency to the main motor may changes

from 20 to 40 Hz and its nominal speed is 1500

RPM. With some calculations time the circuit needs

to set the position of servo motors in the equation 3.

mSecSecDeffTcross

H

HD

DDeff

41.0

360

16

100

90

(3)

where Deff is effective width of proxy switch which

can sense the cams and Tcross is the time control

board which must set all four servo motor positions.

MODBUS protocol in these servo drives need ten

Bytes to be sent through the serial port with 115200

baud rate and also ten receiving Bytes are required

from each servo drive, which shows the correct

command and setting of position; also, the following

simple calculations can be assumed,

mSecBaudrate

NDNBTm

ND

NB

Baudrate

5.5*8**2

4

10

115200

(4)

where NB is number of Bytes per communication,

ND number of servo drives and Tm is the time all the

commands are sent for all servo drives through the

communication port. After all, at the maximum

speed of communication and minimum speed of the

motor, equations (3) and (4) demonstrate that servo

positions may not settle position at the proper time.

All corner cases calculated as following equation,

mSecTcrossmSecTm

SlowSpeedSlowBaudrate

mSecTcrossmSecTm


mSecTcrossmSecTm


mSecTcrossmSecTm


2,5.5

:1200,:115200

4,5.5

:600,:115200

2,139

:1200,:4800

4,139

:600,:4800

(5)


28 | P a g e

As shown by these calculations, there is no way for

MODBUS to set servo positions at the proper time.

Therefore, the control board must send the position

commands through digital inputs of drives. As a

result, when the system is initialized, 15 positions

are defined and saved at the servo drive parameters.

Now, control board can call these positions to be set

by seven digital inputs of each drive. The maximum

number of positions which may be set through these

digital inputs is 64. So, the total angle cycle of 70˚

can be divided to steps of 1.09˚; however, it is not

necessary because mechanical resolution of the

comb “A” just needs a 4.66˚ angle for each step. But,

the control board is extendable to higher resolution

for future works.

3.3 Pattern Programming

All industrial operators respect user-friendly

systems. This feature has the software to accept the

desired pattern by simple rules defined in this paper.

First, the operator defines the pattern on his/her

mind and some rules are followed convert them to

some sequence of steps which should be done by

servo motors. However, the operator must know

how to represent the pattern in servo steps. For

example, s/he calculates the number of steps 1080

for each servo motor and follows the sequence in

Figure 10 which shows one cycle of steps for each

of them separately. Four different programs must be

written by the operator for servo motors which are

equivalent to the special sequence of that servo

motor. First, the basic rules of pattern sequence

programming should be defined in the propose

software: the program must start with the command

START, program must end with the command END.

The Sn command is used to show step number n, Rm

command is used at the end of line and that line is

repeated by m, RAx command is lonely in a line;

then, the program repeats all the steps from START

command to this line. Assume that, for making a

desired pattern, the total step sequence of each servo

motor must contain 240 steps. To understand the

above programming rules, Table.3 is noted by the

equivalent program for step sequence of the servo

motor.

3.4 Communication Protocol

It is essential to avoid any faults in the wrong port

connection and high-speed low-time cost and low-

noise communication protocol. The proposed

system does not use any pre-known protocols;

instead, it uses new special high-speed one shielded

to reduce external noise effects. Supposing that all

four programs of part C are compiled with no errors

and would be downloaded to the control board; if,

the simple serial protocol is used by the system, then

it must send one byte for each step of the sequence.

Finally, the software must send 960 (240×4×1 bytes)

bytes so as to communicate all servo procedure

command to the control board. As explained in

details, the new protocol only requires bytes for

sending all these commands to the control board.

The proposed novel protocol can be explained by

following equations and Figure 11. Each of the four

sub-parts of the final code (C in Figure 11) introduce

a compiled program code in the new protocol. The

first byte of CS1, as shown in Figure 11, is 251,

indicating that servo motor No.1 starts step sequence

code; this is similar for all CSi. CSi is the compiled

program code for the ith servo motor. All bytes of

CS1, between 251 and 250, include the step

sequence of servo No.1, and this is the same for all

CSi. The next part of the compiled code starts with

250, if following byte comes with zero; then, all the

bytes of CS1which are between 250 and 249 include

a repetition number for the first part. It should be

noted that the decreasing amount of start byte of

each part for the ith servo motor is i. Since


29 | P a g e

Fig. 6: Top view of the control board and terminals

Fig. 7: Four cams on the shaft and proxy switch design

Fig. 8: The control circuit

Fig. 9: The woven materials and machine view

Fig. 5: Simple control chart and interrupt list


30 | P a g e

communicating information between PC and control

board has two different parts of control and

monitoring data frames, two different frames of data

are required to be defined. Control frame includes

any data for the control board to control the system.

As an example, the step sequence of all servo motors

must be sent through control frame; the control

board saves data in E2PROM and calls them back to

be execute. For any 100ms, the control board sends

one monitoring frame to the computer; therefore,

Labview monitoring tab is updated 10 times per

second. Speed, status of all LEDs and all servo

motors, servo motor positions, fault codes and

remaining steps are the most important parts of the

monitoring frame. To avoid any kind of overlapping

in the control and monitoring frames, first, Labview

sends a simple frame in order to activate exchange

of the monitoring frame. Activating frame is 0XF1

0X01 and deactivating frame is 0XF1 0X00; 0X

means Hexadecimal view of the byte.

Table 3. Examples of servo motor step sequence program

Servo No.1 Servo No.2

START START

S8S15S1S4S11->R12 S5S7S11S1->R15

RA3 RA4

END END

Fig. 10: An example for servo step sequences

𝐶𝑆1 251 𝐵11 . . . 250 0 𝑁11 . . . 249 . . . . . . . . .𝐶𝑆2 252 𝐵21 . . . 250 0 𝑁21 . . . 248 . . . . . . . . .𝐶𝑆3 253 𝐵31 . . . 250 0 𝑁31 . . . 247 . . . . . . . . .𝐶𝑆4 254 𝐵41 . . . 250 0 𝑁41 . . . 246 . . . . . . . . .

𝐶 = [𝐶𝑆1 𝐶𝑆2 𝐶𝑆3 𝐶𝑆4]

Fig. 11: The program coded in the new protocol

Fig. 12: Control data frame (a). High part (b). Low

part

Fig. 13: Monitoring data frame (a). High part (b). Low

part

4. Conclusion

In this paper, a conventional purely mechanical

dobby knitting machine was automated. The early

methods of controlling the mechanical process did

not have any chance of changing the pattern; also,

they were not flexible for pattern programming by

the operator and user friendly. New simplified

programming language, new communication

protocol and simple change of the pattern were the

most important areas of novelty in this paper. The

new protocol was able to code pattern program and

transmit them much faster and safer while it uses

almost one percent of the transmitting codes of the

other protocols, such as MODBUS. The proposed

method for the automation of purely-mechanical

dobby machine reduced 50% of operator mistakes

and 20% of the maintenance costs.

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