Extreme increases in energy prices and a growing uncertainty concern almost every industrial sector. Online quality control in textile production processes is suddenly more important than ever before.
Leading industrial companies are thinking ahead, producing in a sustainable way before they are forced to, and introduce automated processes and high-tech networked devices to perform live data analysis.
»The key points are the correct collection, analysis, and treatment of the right data as well as the seamless transition of data flows between machines, company divisions and to other companies such as customers or suppliers.«
Industry 4.0-compliant quality control systems from Mahlo GmbH + Co. KG, Saal/Germany, which are installed throughout a textile coating line, show the variety of options to control a production. To adapt to the different needs, the company has a broad portfolio of intelligent scanners and sensors in the Qualiscan QMS system. They record product and process parameters online, such as basis weight, add-on weight, thickness, moisture content, web temperature, residual moisture, exhaust air humidity, air permeability etc. at different stages of the production.
The measured values are processed directly in real-time processors of the sensors. The finished measurement data is visualized internally in an intuitive control display or transmitted via interfaces (OPC-UA, Modbus etc.) to an external network. The implemented automatic control algorithms interact directly with the suitable actuators of the textile coating line and reduce deviation from the target and thus, results in a more uniform end-product. This allows optimized target value specifications and, in addition to better product quality, leads to significant savings in raw materials and energy costs. Furthermore, process reliability and production throughput increase.
Additionally, an important function of any quality control system is to provide detailed historical data. By a simplified and direct data exchange, the end user can keep track of where and especially how its product is fabricated. In this way, a trouble-free value chain is guaranteed, and the end user can also be sure that its fabric is always produced with the right parameters.