Process control is regarded as a one of the most vital
aspects of quality assurance operation. For example in the case of textile
operations, like batch dyeing, there could be many variables which are under
the control of dyer's, but there would be many more that are not. Typically
these factors interact in a a complex way. That is the reason why a dyehouse
having its eye on future must have better process control systems. Recently
control hardware has made great advancements. The emergence of cheap,
dynamic, high speed digital micro-processors has made easy different dyeing
applications. Micro-processor hardware has been now developed to a very high
state of performance and reliability.
A typical control system includes micro-processors that has:
- Control algorithms along with interfaces
- A state of the art multichannel l/O that comes with two way digital/
analog conversion
- Having communication abilities that are both synchronous and
asynchronous
- Monitoring and sensors, that comes with interfaces
- Process devices (e.g. pumps, valves)
- Networking capabilities upload/download
The Control unit shown in the diagram consists of a Computer that has a
very latest advanced touch screen user interface. It also consist of a main
control unit or MCU. The dyeing programmes and other necessary parameters
are loaded completely into the MCU. The MCU automatically controls the
program. It runs in tandem with the PLC-control unit. Which effectively
means that the machine can function independently of the computer. The
control system is totally networked to the main automation control station,
so that there can be easy inter-access of data along with the option of
operational accessibility.
These
days dyers are relying more and more on digital process control system
to increase efficiency and product quality along with reduction in
utility and production costs. Using a reliable control system, variables
like temperature is controlled automatically and accurately. 
Features of the Control Unit