TEXRAY Over View TexRay The product work as a tool, towards applying the scientific approach in e ngineering, maintenance

and production Vs profit, analyzing the textile industry. It provides the customer w ith easy to apply tools, and information systems to achieve miracles in textile engineering. Many of our customer buy the product initially with the purpose of power saving related applications, later they explain us this is an innovative tool to textile not just only for power saving but also for the results it yields. Power analyzing applications are very easy and efficient in Texray and saves lot of time and mon ey. The development of the Texray begins with the purpose of providing it as a teste r for maintenance and engineering analysis, just like an Evenness Tester that is for Quality improvement. Even in the Quality, current trends are in online quality monitoring. Online mon itoring is getting more important as offline monitoring samples just cannot control quality beyond certain extent, or we can take action after that is happened.With present possible technologies, quality control providers are starting with the o nline monitoring provisions. With the input of online trend, Kalki takes challenge to provide a product with all advanced requirements required to use the tool more easily with online on every machine. This makes Texray a tool with 100 % online monitoring for the maintenance and engineering Since Texray is a online monitoring product, it is already collecting production and stop information (for the purpose of generating the maintenance and power graph) at a very high accuracy than the con ventional production monitoring products. Kalki added up the production and stop monitoring a part of the Texray . Fortunately, Texray production reports becomes one to one match with machinery manufacturers results, which so for not possible with conventional monitoring. Since one of most consumed energy in textile next to Electrical energy is compre

ssed air and it is most wasted than the electrical power, we include the compressed air monitoring to every machines but as an option only. Customer can decide to which machines more importance should be given. Towards the best pay b ack performance Kalki recommends use of compressed air monitoring to machines that are consuming 25 CF M or more( MJS, MVS, Auto winders, Texturizing machines Etc), so that it yields the maximum result of our product to the customer. TEXTILE UNDER A SINGLE MONITORING ENVIRONMENT Even for just production monitoring the conventional production monitoring providers give several products for several m achines. But Texray is a single product for all departments from Blow room to finishing process (including looms , Knitting, MVS, texturizing etc). This is to eliminate the different reports and different computers for mon itoring and integration. What Texray can do for textile ? We simply tell to our early customers that, amount same as evenness tester was d one in quality When the results becomes reality, customers give us many applications where they can use this tool to improve, and improvise the profitability of the system. Those feed backs are beyond our expec tations, and it makes us more confident in promoting Kalki s Texray, the real tool to effectively control the textile, and ma kes it one stop solution for all problems Many customers use this tool to achieve the profit oriented productivity, instea d of just being a production based manufacturing. We just want to give more technical details of measuring and outputs from the ka lki before going in detail in the Application.

TEXRAY

ARCHITECTURE:

As shown in figure 1 Texray contains 5 technical layers in the system : Sensors and Sensor Less interface systems. Dual core 5 function embedded CPU card.

PLC based data storage towards the effective data storage to with stand the powe r failures. Windows based server programs with multithreading enabled core server programs for trouble free interfacing and working Developed with Advanced mainframe Programs which are bac k bone of our structure. Windows based client (kalki online) a very new concept for textile with advanced features.

KNOWING MORE ON TECHNICAL LAYERS: SENSORS: As shown in the figure two, we have three kinds sensors adaptation in technical module. 1 Physical sensor interface (applicable for current sensors , voltage interface , Flow sensor )for Power and Compressed air monitoring. 2 Sensor less interface for interfacing the machine s production and stop sensors without installing an additional sensor for the same purpose. This is first of its kind for any automa tion industry with Kalki s advanced technology. 3 Analog sensor interface for measuring the temperature, vibration, air pressure etc for the machine doctor function. (Maximum 8 analog output sensors per machine of any combination permit ted).

DUALCORECPU: This is an specially designed microchip, with twin processors inside the single

chip. Which does 5 functions. 1 Power Scope at the highest quality of 8000 scan / per sine wave, and power con sumption at very high accuracy of 0.01 W ( conventional Class 1 meters at 1 % accuracy or we can say 1 0 W / 1KW). When technically differentiate the Conventional energy consumption power meter and kalki power gr aph generator, Kalki s power monitoring is doing the functions of the Power scope( Like a LOAD MANAGER) but t he Energy consumption meters does the function of mechanical watt meters digitally. 2 Air Energy scope it is very similar to the Power graph , but it is interfaced to the flow sensor instead of a current transformer.

1. Production e data to PLC

Measuring and calculating the production parameters and storing th

1. Stop Classify the stop data reason wise with duration and averaging data. Wit h elimination limitation convention stop monitoring systems. Standard 4 stop interface or 8 st op interface. 1. Machine doctor which receives the signals from 8 analog sensors and perform t he actions which are tailor made. PLC BASED DATA INTERFACE: PLC is to perform the data hub function with additional control functions if req uired. Each 24 machines will be individually connected to a single PLC, Each PLC will be Serially connected to t he Server .

SERVER: It is a software layer, which have the capacity to share the multi core CPU feat ures effectively. Since the software developed with Main frame languages advanced than the conventional monitoring so ftware, allows the customer use the server for other application even when server working. Customer can oper ate the server to get reports or data manipulation at the same time of communication of jobs. KALKI ONLINE : It is an client interface system for kalki products for all industries including textile, Since Texray is also an product inside kalki online client interface module. With the new concept of single client software for all kalki products, it aims t owards eliminating N number of systems and easy operation of view or edit the complete reports and data in sing le system environment. With a Jewel for LAN based environment, Single login with multiple rights to ind ividual users wise programmable on multiple products. User wise language selection option enables all levels of user can use the system without language barrier. Provide the customer with the option to change the menu and field names in entry menu or in reports for their easy words.Editable formulas to formulate the reports to the customer or country stan dards. Web interface due to the advance in technology of information communication, kal ki is the first to provide the web scoreboard to current performance of the machines on web, when and where it is r equired. (In future available only on executive version of kalki online) SMS Short message alert system with easy to use NOKIA phone interface module wil l help the customer use this rich feature at just less than 6 USD a month expenses. (In future available only exec utive version of kalki online) Auto email system The regular numerical reports or malfunction graphical reports can be sent by email, to enable the user to get the reports immediately, without waste of time and paper. (In future available only on executive version of kalki online)

OUT PUT FROM THE TEXRAY 1. GRAPHICAL OVER NUMERICAL

Power Texray reports either a production/energy report or stop analysis reports as shown in figures are embedded with graphical support. For every variable parameter columns customer can click and s elect the graphs of between machines or for particular machine in long term. This graphical future is to reduce the customer data analyzing time to locate th e deviations in few seconds. Which will reduce the requirement of additional excel converters and report formation, howe ver customer can save the data from any report to excel. Click and send email future on reports with remarks or message more like an stan dard email future with attached reports. This is part of the standard system.

TEXRAY DIAGRAM:

The important part of the Texray is the Texray diagram, which is the basic outpu t from the system which will help the customer to use this as a tool. It provides curve of energy (electrical and air) versus the speed of the machine with production based (like cop content or bobbing content). The Texray Diagram first of its kind eliminates mos t manual operation required to study the machine. Since it provides the graph for production in every machine in a minute interval , it makes the Texray an fully online tool which will help the customer to locate the cost saving point either of power or maintenance malfunctions etc. Additional graph on the Texray with formula (programmable), which may be a simpl e UKG graph or a production costcurve at the different speed and different produ ction conditions. This will directly help the low technical financial management peoples to assess the profit oriented productivity.

TEXRAY DIAGRAM FOR OE DIVISION :

TEXRAY GRAPH FOR OE DIVISION:

The reports can also be exported to excel and can be viewed for our convenience: The following is the report for the carding division: DAY MACHINE

MCNO DEPTNAME PCOUNT MATERIAL PRODWT PRODHRS TOTPOWER TOT_LEN UKG AVGMMI DK1 CARDING 0.095 oe cotton 1141.17 962.04 126.8316 183539.3844 0.1111 189.0789 DK2 CARDING 0.095 oe cotton

1114.62 956.02 118.09 179268.5715 0.1059 182.6041 DK3 CARDING 0.095 oe cotton 1229.46 1021.04 129.6883 197738.1531 0.1055 188.9309 DK4 CARDING 0.095 oe cotton 1160.39 1028.02 127.5376 186631.5391 0.1099 175.4811 DK5 CARDING 0.095 oe cotton

890.82 757.98 101.7752 143276.0853 0.1142 186.1052 DK6 CARDING 0.095 oe cotton 1171.9 1006.98 121.5003 188483.2202 0.1037 181.8776 DK7 CARDING 0.095 oe cotton 1062.44 962.98 125.3373 170876.9692 0.118 173.6141 DK8 CARDING 0.095 oe cotton

941.01 859 121.7211 151346.8035 0.1294 164.6024 DK

APPLICATION OF TEXRAY: Application of the Texray system is wider and unlimited, and it can be expanded by the technical knowledge of engineering maintenance persons. We provide here the very basic applications. Before discussing in detail, we explain the hurdles in engineering, maintenance departments that reduce the scientific approach towards the goal. MAINTENANCE: 1 Most of the maintenance in industry is based on the manufacturer s recommendatio ns and remote controlled by quality reports. When we originally look at these issues, quality deviation i s the net result of the maintenance defect. Unfortunately engineers are limited only to those criteria. But original ly maintenance deviates well before the quality variation occurs. 2 Spare parts are replaced based on the global suggestions or based on approxima tion and vary from mill to mill. But originally some spare parts costs are very negligible when compared to how much the power it wasting additionally. 3 Time taken to know the problem or spare parts failure occurs infinite, it will come to notice only in next maintenance or quality test or by noise or when a next level serious damage occu rs ( like a simple motor bearing damaging the motor coil). But power loss or quality variation starts significant ly at the small levels of problems which in no way can be located by any current systems. 4 Effect of wrong mechanical settings or best settings unknown. 6 Selecting the spare parts is presently done only based on the quality, and qua lity based durability. Surprisingly many spare parts providing the best quality even in long run, but i t consumes excessive power after some period is over and it becomes costlier than that cost of the spares itself.

ENERGY: Scientific approach in the Energy department is very limited, even though which is most costly overhead of the company . Even the Energy Cost of the Ring frame for Three years is more than the machine cost in INDIA(based on LR 6 Machine @ 40 Nec warp). Engineering department is wi th very limited tools and it consumes time and human work involved. Most of the mills Equipped with Load managers, can provide the data of one singl e machine at a time, and needs at least 1 day per machine. Analyzing the group of machines may take a week or more. This prevents

the engineering department to locate the fine variations of below 3 to 5 % . Most engineering departments studies needs a long meeting with the maintenance p roduction department to convince, and many attempts failed since the data is not long term and limited. So many production and department variation occurred during study. Which is very normal to reject many studies which have suspicions and floating data Current tools require experienced man power, or the several peoples work togethe r to study the single machine. Basic Electrical and computer intelligence is a must for use these tool s. Which limits continues studies.

5 Most of the assessment of maintenance or maintenance team performance is by th e human data. But it is misleading in many occasions.

It is very difficult to reconfirm the action, since only long term data can say the reality, it is absolutely difficult to assess the performance after action. REMEDY FOR LIMITATIONS: 2 The Data and graph will be available in memory, permits even the backward anal yzing. 3 Data readily available in graph form, which enables the user can directly, use the data and needs to perform action only. 4 Automatic alerts on advanced communication networks like SMS, WEB provides the complete controls of present possible. 5 Advanced graphical tools on every numerical data, requires seconds to make the graphical forms of any data to analyze anything in long term.

APPLICATION OF TEX RAY: POWER COMPARISON AND OPTIMIZATION: In reality there will be at least 2 to 5 % variation between the machines to mac hine even though they are from the same manufacturer and running the same material and count. These variations are the r esults of spare parts or defective parts or defective settings. Such small variations can be identified when these machines data analyzed in lon g term, surprisingly even 2 % variation costing 7000 units per annum in 1000 spindle ring frame. In practical elimination of such variation not much difficult, but in most of th e experiences locating the problem after confident study was very little. Many cases customer run the machines with higher doff content, which means the h igher production, lower the man power cost and lower joints at winding. Yes there is a saving on the above, but when we analyze what we lose on power is almost 4 times the cost the what saving achieved in the earlier method. It becomes possible and required to optimize the production content for differen t counts and on different machines where the more saving and better profit is possible. Cost of manufacturing with critical spare parts like spindle and ring versus lif e time : Practically. Life of the spare parts like Ring is decided based on the quality a nd running performance in terms of

yarn breaks. When see with Texray so many miraculous things identified. Even at the same qual ity and same production performance, Excessive power cost of those longer life parts is more than that p art cost with in a year. It shows the every spare parts life must be decided based on the Power also, sin ce effect on power is occurring well before on quality and production. This is one of surprise information comes out from the textile industry after in stalling the Texray system, which makes tremendous changes in Ring Changing and selling markets.

1 Texray provides most advanced Graph which carry the speed versus production, p ower and production cost curve for every machine and for every production minutes. POWER VERSUS PRODUCTION CONTENT OPTIMIZATION.

MAINTENANCE DURATION: Many cases found improving the maintenance routines, giving more saving on power which is much higher than the total maintenance cost with immediate effect. But when we see in long term more benefi ts on failure of parts, and more consistent in quality occurs. With this scientific approach, customer achieves cost savings with improved perf ormance , this kind innovations are most required for current textile industry. PROFIT VERSUS PRODUCTION: Many companies say in past, before the Texray and power crisis, higher productio n means higher profit. That may be true to some extent, but when we look at very closely there is scope to optimize the speed pattern based on profit. Most of Texray users now reduced the higher machine speed to optimize machine sp eed for different count, since the power curve rising abnormally beyond certain speeds and eating up the profit . With lively analyze of the machine and immediate reports and customer can optimi ze with in two doffs of what they want. Even the market condition or selling margin of yarn involves in running speed of the machine, since the power consumption is very high at very high speed which some time consumes portion of the profits MAINTENANCE CONTROL ROOM: When Texray starts working in the textile industry , The engineering and the mai ntenance departments are surprised to see the results it produced and work round the clock to eliminate all the proble ms, since they could able to see the total abnormalities in the mills, like power loss points, improper settings, maintenan ce variations. This takes several months for the team to bring the mill to uniform, which produ ces the engineering departments with huge saving and knowledge. This makes most of our customer places creation of MC R chaired by Engineering and maintenance Professionals. 1.Shows effect of Spare parts worn out like a bearing ,and in next day reports e nable them to take quicker action, which saves power and side effects. 1 Any improper setting after the maintenance or production setting visible. 2 Even Small yarn choking in main motors can be viewed from the power graph. 3 Feed back of maintenance and break down actions available in next day reports. 4 Assessing sample trial spare parts in a day results in selecting spare parts i

n scientific way. 5 Saves the critical parts failure with the immediate information even by SMS wh en the abnormalities occurs. 6 Continuous improvements on machines possible, which is responsible for consist ent quality at the very effective cost control. 7 Assists the financial department or cost controllers with yarn costing and rea lization.

With Texray customer can optimize the maintenance in terms duration and durabili ty versus the cost of the maintenance and man power cost. Regular inspection of Texray diagram and Power reports become routine jobs to th em, which provides them the following information.

COMPRESSOR CONTROLS INSIDE THE TEXRAY: By using the results customer can optimize the compressor performance in followi ng ways. 1 Analyzing the installation conditions, whether the direction and location is f it for proper efficiency. 2 Comparing the compressors for efficiency in the system. 3 Analyzing the maintenance and maintenance effect, to fix the required schedule . 4 Spare parts durability and selecting the right one. 5 Selecting Right compressor based on long term cost saving.

GENERAL PRODUCTION AND STOP MONITORING SYSTEM: Excellent reports and data interface system eliminates the requirements of any m anual operation needed in production data collection and feeding system. With the all the applications , Texray does More accurate production and stop mo nitoring with help highly advanced measuring and data capturing technology. Which provides the customer wi th the ready to use production data system with one to one match with the hang meters.

Compressor will be treat the Texray as part of the machinery, and it provide the valuable information of production of air versus power in time graph continuously. It also measures climatic condition s on the machines.