Centralized HMI and PLC control for weaving machinery

Application Overview

Modern textile manufacturing environments require highly flexible control systems to manage alternating materials and intricate knit patterns without mechanical downtime. In this field deployment, an automated weaving machine is engineered with Samkoon’s SK-070ME HMI and high-speed FAs-20MT-AC PLC matrix, synchronized with dual variable frequency drives (VFDs) to execute deterministic execution control over knitting and jacquard weaving processes.

By adapting the raw material stock fed into the machinery layout, operators can reliably switch between distinct production matrices:

• Standard Weaving Matrix: Utilizes a single baseline yarn material.
• Jacquard Weaving Matrix: Coordinates three distinct yarn variants simultaneously.
• Specialty Steel Scrubber Fabric Matrix: Feeds heavy-duty yarn as the main matrix material, high-tension steel wire for the jacquard patterns, and protective plastic filaments for the structural knitting.

This robust physical setup enables machinery exporters to adapt production paths, expanding capabilities from conventional fabrics to complex metal-fiber industrial cleaning grids.

System Configuration

• HMI (Human-Machine Interface): Samkoon SK-070ME (Industrial 7-Inch Touchscreen)
• PLC (Programmable Logic Controller): Samkoon FAs-20MT-AC (Compact Controller Mainframe)
• Drives & Motion Componentry: 2× Heavy-Duty VFDs (Dedicated for Main Drive Motor and Feed Motor Regulation)

Process Flow: Knitting & Jacquard Integration

The control architecture coordinates the manufacturing sequence into two independent, tightly interlocked cycles: the Knitting Process and the Jacquard Process. Prior to initializing the hardware drive line, operators program critical threshold parameters directly into the HMI register cells:

• Knitting and Jacquard Target Loop Counts
• Jacquard Cyclic Switching Intervals
• Nominal Main Motor Base Frequency & Core Feeding Frequency Values
• High-Tension Feed Acceleration Frequency Limits

Step-by-Step Operation Sequence:

• System Initialization: Pressing the physical Start button triggers the main motor drive line to run the pre-set knitting loop sequence.
• Active Knitting Phase: The automated knitting solenoid lowers the mechanical material feeder while jacquard solenoids 1 and 2 are simultaneously energized to guide the stock.
• Transition to Jacquard Phase: Upon registering the target knitting loop count, the PLC logic executes an immediate transition—the knitting solenoid lifts, the main jacquard line solenoid lowers, jacquard solenoid 1 remains energized, and jacquard solenoid 2 is safely disabled.
• Cyclic Jacquard Switching: As the localized switching loop counter trips its boundary, the PLC alternates output states—disabling jacquard solenoid 1 and enabling jacquard solenoid 2 in an automated, non-stop production cycle.
• Hardware Cycle Reset: Upon completion of the absolute jacquard loop threshold, the control loop auto-resets—lowering the knitting feeder and re-energizing both jacquard solenoids 1 and 2 to initialize the next product batch.

Real-Time Fault Interlocking & Tension Automation:

• Yarn Break Active Protection: If the localized limit sensors detect a material tear or thread break, the FAs PLC instantly executes an emergency stop rung, pausing the drive line. Following reconnection, pressing the Start button resumes operation from the exact point of the interruption without data corruption.
• High-Tension Frequency Scaling: When material tension spikes and triggers the fast-feed feedback signal, the PLC automatically scales the velocity curve—instantly adjusting feed speed based on the combined baseline feeding frequency and pre-configured acceleration steps to mitigate material wear and wire snapping.

Solution Highlights

• Integrated Control Footprint: Fusing a 7-inch industrial display with a compact FAs processing loop and dual-VFD synchronization removes external communication handshake latency and ensures continuous runtime reliability.
• Multi-Material Component Sealing: Natively supports high-tension wire, coarse plastic filaments, and fine yarn combinations without triggering component degradation or sensor drift.
• Deterministic Fault Trapping: High-speed input monitoring locks down the machine layout immediately upon material failure, providing resume-on-repair logic to protect operational margins.
• Dynamic Velocity Tracking: Real-time register-mapping seamlessly tracks tension variations, scaling the drive output dynamically to prevent wire warping and surface friction.

Conclusion

The Samkoon HMI + PLC + VFD control architecture delivers a safe, rugged, and highly adaptive automation standard for international weaving and textile machinery. By replacing loose, fragmented control links with customizable loop parameters and integrated digital protection rungs, this solution provides global machinery exporters and system integrators with a cost-optimized, higher-ROI path toward high-capacity specialty textile automation.