INVT Modernizes Power Loom Automation for an Indian Manufacturer

Abstract: The solution of the INVT AX72 PLC, DA200 servo, GD200A VFD, and VS-Q HMI creates a high-performance, precision-driven automation architecture. For power loom and heavy-duty metal machine applications, this ecosystem replaces traditional mechanical drives with synchronized electronic control, significantly increasing tension accuracy, production speeds, and operational reliability.

Keywords: DA200 Servo, Machine tools, AX72 PLC, E-Cam, Position Control, high precision, VS-Q HMI, INVT HMI, Codesys.

Project Background:

This OEM is a prominent local manufacturer and OEM supplier of power loom machines and automated systems based in Boiser, Maharashtra. These looms are highly regarded in the pharma and steel industries for their durability, cost-effectiveness, and low power consumption.

Customer Requirements

The customer’s existing machines was totally on either Embedded control based or mechanical cam-based control system, which only supports fixed job profile, No flexibility of operator control. Customer’s requirement is to develop a customize solution for a power loom machine majorly focus on high-precision motion control, robust multi-axis synchronization, and reliable integration of drives and PLCs.

INVT Solution

Solution Overview:

An INVT automation solution utilizing the AX72 PLC, DA200 servo, GD200A VFD, and VS-Q HMI delivers high-speed, synchronized control for power loom and metal working m

achines. It maximizes production efficiency, ensures precise tension and positioning, and drastically reduces mechanical downtime.

Solution Advantages:

• The AX72 PLC utilizes EtherCAT networking to tightly coordinate the DA200 servo axes. This ensures perfectly synchronized weft insertion, tension control, and metal wire take-up without the latency of traditional pulse-control systems.

• The GD200A VFD provides exceptional open-loop vector control, producing high starting torque at low speeds. This perfectly handles the main motor which can easily drive the heavy mechanical assembly of loom machine.

• The built-in electronic cam functionalities with slave absolute function as well as editable cam table allow you to easily change the design of job. This makes accurate weaving.

• The DA200 features a 23-bit absolute encoder for full closed-loop control. This provides exact spatial positioning without the need to recalibrate the mechanical origin after a power cycle.

• The VS-Q HMI simplifies complex setups. It features recipe storage for different metal weave patterns, real-time status monitoring, and easy-to-read fault diagnostics directly from the shop floor.

• EtherCAT topology greatly simplifies wiring, minimizing hardware wear-and-tear. Components are built to handle the rigorous duty cycles and high-vibration environment of powerloom metal machines.

Solution Topology:

System Commissioning

Control Panel

Solution Value

• An INVT automation solution for power loom machines—leveraging the AX72 motion PLC, DA200 servo, GD200A vector VFD, and VS-Q HMI—delivers high value by ensuring precise metal fabric tension control, synchronized electronic let-off/take-up, and pattern consistency, ultimately boosting production speed and quality.

• Provides high-speed processing up to 1ns and supports 100ms real-time synchronization via Ether CAT. It flawlessly manages complex weaving patterns, weft insertion, and electronic cams.

• Offers full closed-loop control and fast response. Its high-resolution encoder (up to 23-bit) ensures precise warp/weft tension and accurate folding, drastically reducing yarn breakage.

• GD200A handles the main motor with excellent vector control and low-speed torque. Its built-in loom industry-specific protections manage heavy, fluctuating loads and extreme ambient dust.

• VS-Q HMI is a industrial touchscreen that acts as the central brain for parameter entry, batch monitoring, and storing weave recipe data.

• This suite allows for a seamless, cost-effective upgrade to fully automated, high-speed computerized looms without relying on only one solution.

Conclusion

The INVT automation system suite provides a high-performance, cost-effective motion control solution for modern power loom machines. It replaces mechanical linkages with digital synchronization, ensuring constant fabric tension, exact pattern repeatability, and increased weft insertion rates. Unlike traditional mechanical loom systems, this solution delivers stepless weft density variation, fast style changing via HMI recipes, and increase productivity, customer is very much satisfied with INVT solutions.