Lakshmi Electrical Construction

Sizing Machine PLC Conversion System – Precision Automation for Warp Preparation

Our Sizing PLC Conversion System is designed to modernize conventional sizing machines by replacing outdated relay-based, manual, or analog control systems with a fully automated PLC and HMI-based solution. This conversion ensures accurate size pick-up, uniform warp tension, improved production efficiency, and enhanced operator safety, making it ideal for textile mills seeking reliable warp preparation performance.

The PLC conversion enables precise control of speed synchronization, tension regulation, drying parameters, and chemical application, resulting in consistent sizing quality and reduced yarn breakage.

Key Features of Sizing PLC Conversion System

• Advanced PLC-based control architecture

• User-friendly HMI touchscreen interface

• Accurate speed synchronization from creel to weaver’s beam

• Precise tension and size pick-up control

• Integrated safety interlocks and alarm management

• Real-time monitoring and production data display

• Energy-efficient operation with VFD integration

• Reduced wiring and simplified maintenance

Sizing Machine Parts Covered in PLC Conversion

Our PLC conversion system integrates and controls a wide range of sizing machine parts, including:

Drive & Motion Control Components

• Main Drive Motor

• Creel Drive Motor

• Size Box Drive Motor

• Squeeze Roller Drive Motor

• Drying Cylinder Drive Motor

• Delivery Drive Motor

• Beam Winding Motor

• Variable Frequency Drives (VFDs)

• Encoder Feedback System

Sizing & Warp Processing Components

• Creel Stand Assembly

• Tension Control System

• Size Box Assembly

• Immersion Rollers

• Squeeze Rollers

• Drying Cylinders

• Expansion Unit

• Split Rod and Leasing Unit

Electrical & Automation Components

• PLC Controller (Siemens / Delta / Schneider options)

• HMI Touch Panel

• Electrical Control Panel with MCC Section

• Power Supply Modules

• Relay and Contactor Modules

• Proximity Sensors

• Limit Switches

• Safety Relay Modules

• Emergency Stop Circuit

Monitoring & Safety Components

• Yarn Break Detection Sensors

• Warp Tension Sensors

• Temperature Sensors for Drying Zone

• Moisture Monitoring System

• Overload Protection System

• Alarm and Status Indication System

Benefits of PLC Conversion for Sizing Machines

• Uniform size pick-up and improved warp quality

• Reduced yarn breakage and production losses

• Stable machine operation at higher speeds

• Faster fault diagnosis and troubleshooting

• Lower energy consumption

• Enhanced operator safety

• Extended machine service life

Applications

• Cotton and Blended Yarn Sizing

• High-Speed Sizing Machines

• Slasher and Sectional Sizing Machines