Instead of replacing the entire machine, we simply swapped out the electrical panel on the manually operated unit.
We’ve upgraded the system by replacing the old PLC, control switches, and relays with brand-new components.
1. ForTex DiF
The ForTex DiF is a controller developed specifically to automate differential gear-type jig dyeing machines.
It offers advanced features such as stepwise temperature control,
automatic water supply and drainage,
and an "overflow rinsing" function designed to conserve water.
Unlike conventional jig dyeing machines with single or dual drives that have dominated the market,
differential gear-type machines have traditionally lacked automation.
The ForTex DiF fills this gap by enabling full automation for these machines.
2. Manual Operation Process Overview
After loading the fabric, water is manually filled into the machine, and the dye or scouring agent is also added manually before starting the process.
The process waits until the temperature reaches 60°C. Once it does, the temperature is raised to 80°C while the machine performs one rotation.
After completing one rotation at 80°C, the temperature is increased to 97°C and the machine performs six rotations. (The process starts immediately without waiting for the internal temperature to reach exactly 97°C.)
The machine maintains an internal temperature of 97°C and triggers a "process complete" alarm.
When the alarm sounds, the operator presses the "RUN/STOP" switch to end the process and then selects the next step to proceed.
STEP
COMMAND
SET VALUE
UNIT
1
TEMPERATURE
60
℃
2
STANDBY
0
3
ROTATE
1
4
TEMPERATURE
80
℃
5
ROTATE
6
6
TEMPERATURE
97
℃
7
END
8
When temperature control is activated, the circulation pump automatically starts.
Except for temperature control, all other operations—such as water supply,
drainage, and chemical dosing—are performed manually.
To ensure that temperature control is automatically stopped when the "COMPLETE" alarm is triggered,
the operator must first set the temperature control value to 0°C before entering the [END] command.
Setting the temperature to 0°C indicates that temperature control should be terminated.
