To satisfy the demand for economical dyeing, a semi-automated machine is proposed and tested for results in this research paper. After the initial testing of components, interconnection with the flow of operation must be verified. A Synthetic dye cannot be directly considered for dyeing because of its powered nature. The synthetic dye must be converted to liquid form for an effective dye output. The conversion can be carried out by mixing dye, acid, and water together. To achieve the liquefied state of dye, a semi-automated machine is proposed. Synthetic dyes are resistant to the proportion of the acid mixture. So based on the nature of the synthetic dye, the proportion of acid and water mixture has to be predetermined in the automated machine. The level monitoring is the key parameter in the proposed system which prevents overflow of liquefied dye and checks the correct proposition to which the dye has to be filled. The Ultrasonic sensor helps in checking the level to which liquefied dye can be filled. The verification of the procedure of connection is important to prevent hardware damage. Thus the ultrasonic sensor is interconnected with Arduino in the virtual environment.
Initially, the ultrasonic sensor is interconnected with Arduino in the tinker cad platform and tested for results. The Ultrasonic sensor helps in measuring the distance and reports the measured data back to the controller. To make the user aware of the distance being measured, a liquid crystal display (LCD) is used. The ultrasonic sensor sends high-frequency sound signals and operates with the reflected signal. The time taken for the signal to transmit and reflect back is measured as the distance of operation. The obtained results are shown in Figure 4.
As the ultrasonic sensor has been tested, the pH sensor must be tested with Tinker cad and then the same has to be simulated and tested for results in the Arduino IDE platform. The pH probe contains a sensor electrode and a reference electrode, which can measure the hydrogen-ion activity in a solution. By measuring the voltage generated by the exchange of ions, the pH probe is able to determine the hydrogen-ion activity in a solution. The pH sensor simulated in Tinker cad is represented in the Figure 5.
After the checking of individual sensors, the entire proposed system is tested for results with Tinkercad platform. The proposed system in the tinkercad platform is represented in the figure 6. As favorable results has been obtained with the tinkercad platform, the working of the proposed system is simulated with the Arduino IDE environment. This step of verifying the component interface with softare plaftorm reduces the hardware wastage.
A sample hardware environment of the proposed system is tested with an Arduino board connected to sensors. Figure 7 represents the simple model interconnected and tested for results. A standard immovable base and a plastic setup with a centre sprinkler rod are provided. Outlet and inlet pipes are interconnected at the bottom and top positions of the plastic container, diagonal to each other, to improve the water flow based on gravity. The Ultrasonic sensor is attached to the top of the plastic container and is governed by an Arduino board. The outlet water is stored in a container to test the pH of the outlet solution. Based on the pH level, the technique for recycling water can be chosen. The recycling technique either traditional or modern must provide a zero water discharge condition.
3D model design is important in the implementation of an innovative proposed model. The cylinder with sprinkler rod at the centre with outlet and inlets has been designed with perfect accuracy in measurements using 3D CAD tool. The designed 3D model, figure 8, has been represented in the Figure 8. This makes the manufacturing process simple and clear. The 3D model helped better in identifying the details of the design which in turn supports for the perfect manufacturing of the proposed model. A cylinder with centre sprinkler rod surrounded by coil structure with all overall holes is provided. This structure helps in even spread of colour all over the fabric. The inlet and outlet pipelines of the designed machine are important. Three inlet pipes are provided in a way it gets connected to the centre sprinkler rod, for fast pumping of dyeing solution. Two outlet pipelines are provided for perfect discharge of the dyeing solution after use.
With the help of the 3D-designed model, a hardware implementation has been made as shown in figures 9 and 10.
The detailed internal structure of the proposed design has been represented in figure 10. This shows the detailed internal sprinkler rod with randomized holes which helps in uniform dyeing of the fabric.
The designed model can be thus interconnected to the Arduino board for the providence of an automated dyeing environment.
A. Future Scope
The innovative idea proposed in the paper is for satisfying needs in the first stage. The maximum length of fabric that has been dyed in the proposed system is 6 meters long. This fabric limitation can be further extended to a machine that can dye four, six meters fabric at a time. The automation of mixing dyes with the chambers of the dyeing machine can also be updated further based on the need. Better health protection techniques can be added to the proposed idea. Sensors integrated with the dress material used by the employees in the industries can be added to the project in future to provide a better working environment. This will help in regular health monitoring of the employees. The net production will be improved as if four dyeing chambers are integrated as a single machine. Automatic dyeing in all chambers can be allowed. Filtering and pH retention of the outlet water can be done through improvised techniques. Instead of the traditional filtering and aquaponics technique, a better developed filtering methods can be tested for results. Various filtering techniques can be analysed and the best economical method of filtration can be used as a future work.