Development of a Sensor For Thread Breakage Detection On Overlock Sewing Machine

Introduction

 Why this project? Something Different .Not related to garments directly. Yet no sensor development for overlock machine.

 Overlock machine: 3 thread, 4 thread and 5 thread. Uses of overlock machine. It is difficult in identifying thread breakage. Operator cannot sense the immediate breakage of the thread.

 Fabric gets affected. Thread gets wasted. In this project, a sensor have been developed to stop the machine immediately as the thread breaks.

Objective of our project :

To sense the thread breakage. Developing mechanical and electronic circuit to detect the breakage. To stop the overlock machine immediately after the thread breakage. To save the time in identification of thread breakage. To improve the quality of sewing.

Literature Review

 There is no sensor yet developed in overlock machine. Study of various sensors. 1. Rotary sensor 2. LED sensor 3. Photo electronic sensor 4. Inductive displacement sensor 5. Piezo electric sensor 6. Weft stop motion

7. Capacitive sensor 8. Proximity sensor Selection of appropriate sensor.

PLAN OF WORK

Study of over lock machine

Study of various types of sensor

Selection of sensor

Assembling of kit and sensor

Working of sensor

Making of external stand

Implementation of senor on machine

Testing & Readings

Comparison of the time with & without sensor

Conclusion

Development of Sensor

 Preparation of kit. Components of kit: IC LM324, ICCD4093, Relay unit DPDT, Capacitor, Buzzer, transistor and LED. Assembling of kit in appropriate manner. Preparation of stand to fix the sensor. Set the passage of the thread via the stand and through the wheel. The wheel has metal part fixed at edges of the axis.

Attachment of stand on over lock machine

Proximity Inductive Sensor

The proximity inductive sensor is an electronic sensor which detects any metal object which is nearer to the area of circumference of the sensor.

Working of Sensor

 Principle:
A coil and oscillator creates an electromagnetic field in the close surroundings of the sensing surface. The presence of a metallic object in the operating area causes a dampening of the oscillation amplitude. The rise or fall of such oscillation is identified by threshold circuit that changes the output of the sensor.

Working of Proximity Sensor

Machine on switch on

Thread breaks Pulley stops rotating

Thread doesnt break

Pulley rotates

Metal parts stops

Plastic parts stops

Alternatives high-low pulse

Continuous high pulse

Continuous low pulse generates

No alarm

OUTPUT

LED BUZZER

Output of the Sensor:

There will be pulse generation as an output of the sensor. A.Alternate Low-High Pulse:

B. Continuous High Pulse:

C. Continuous Low Pulse:

Video of working of sensor

Result & Discussion

1.Quantitative:
1. Test on Time required for detection:
Obs. No. 1 Without Sensor (time in milliseconds) 35.5 With Sensor (time in milliseconds) 2

2 3
4 5 6 7 8 9 10 Average

39.6 46.8
55.8 26.5 27.4 33.3 41.8 28.8 37.8 37.33

2 2
2 2 2 2 2 2 2 2

2.Qualitative: a. Needle penetration mark

Without sensor

With sensor

Conclusion

 Use of sensor:
1. 2. 3. 4. Saves time Reduces thread waste Improve the quality of fabrics Increases productivity

Future Scope
Use of other sensors: relay, led, capacitive, etc Automatic stop mechanism Use of different types of indicators Automatic start mechanism

COST SHEET
PARTICULARS PROXY SENSOR WITH CABLE POWER SUPPLY & RELAY CARD QUANTITY 1 1 PRICE 800 1200

COMPARATOR CARD WITH ASSEMBLY

RED 230 INDICATOR

1
1

1500
130

BOX ASSEMBLY & WIRING

ADJUSTABLE NOBS(PRESET) STAND EXPANSES SET UP EXPENSES TOTAL

1
2

350
250 130 100 4460

THANK YOU