DESIGN AND DEVELOPMENT OF AUTOMATION SYSTEM

FOR (CLOTHES FOLDING MACHINE)

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BAKR SAEED RIZIQ DARAGHMEH

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RESEARCH REPORT SUBMITTED TO THE FACULTY OF

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ENGINEERING UNIVERSITY OF MALAYA, IN PARTIAL FULFILMENT OF

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THE REQUIRMENTS FOR THE DEGREE OF MASTER OF

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ENGINEERING (MECHATRONICS)
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2019

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 DESIGN AND DEVELOPMENT OF AUTOMATION SYSTEM
FOR (CLOTHES FOLDING MACHINE)

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BAKR SAEED RIZIQ DARAGHMEH

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RESEARCH REPORT SUBMITTED TO THE FACULTY OF

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ENGINEERING UNIVERSITY OF MALAYA, IN PARTIAL

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FULFILMENT OF THE REQUIRMENTS FOR THE DEGREE OF

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MASTER OF ENGINEERING (MECHATRONICS)

2019

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 UNIVERSITY OF MALAYA
ORIGINAL LITERARY WORK DECLARATION

Name of Candidate: Bakr Saeed Riziq Daraghmeh

Matric No: KQF170008
Name of Degree: Master of Mechatronics Engineering
Title of Project Paper/Research Report/Dissertation/Thesis:

DESIGN AND DEVELOPMENT OF AUTOMATION SYSTEM

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FOR (CLOTHES FOLDING MACHINE)

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Field of Study: Industrial Electronics and Automation

I do solemnly and sincerely declare that:

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(1) I am the sole author/writer of this Work;
(2) This Work is original;

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(3) Any use of any work in which copyright exists was done by way of fair dealing
and for permitted purposes and any excerpt or extract from, or reference to or
reproduction of any copyright work has been disclosed expressly and sufficiently
of
and the title of the Work and its authorship have been acknowledged in this Work;
(4) I do not have any actual knowledge nor do I ought reasonably to know that the
making of this work constitutes an infringement of any copyright work;
(5) I hereby assign all and every rights in the copyright to this Work to the University
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of Malaya (“UM”), who henceforth shall be owner of the copyright in this Work
and that any reproduction or use in any form or by any means whatsoever is
prohibited without the written consent of UM having been first had and obtained;
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(6) I am fully aware that if in the course of making this Work I have infringed any
copyright whether intentionally or otherwise, I may be subject to legal action or
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any other action as may be determined by UM.

Candidate’s Signature Date:

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Subscribed and solemnly declared before,

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Witness’s Signature Date:

Name:
Designation

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 ABSTRACT

Clothes folding machine is developed and designed to overcome the routine task of

folding clothes, because of its highly requirement in our daily life use. The machine

represented a fully automation system that combines the mechanical design with the

electrical control design. the machine was developed to serve the normal people with a

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normal human intelligence so its design was completely representing the manual way of

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clothes folding, and specifically following the steps of folding the sleeves back ward then

folding the lower shirt part and finally try to flip the shirt to its upper face on the way of

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delivering it to the operator. Shirts was taken as the first sample which the machine

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mechanisms designed to fold. Human intelligence was also required to overcome the obstacle

of defining the clothes type and shape. So it was required by the operator to feed the clothes
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with a certain way, then allow the machine to fold it. Using the 3D simulation with the help
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of CAD engineering softwares (solidworks) boost the initial ideas to a desired point to go

through the control part. PLC take a place to control the mechanisms with proper time folding
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and sequence. OMRON PLC CP1L model training kit hardware connected to the CX-
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Programmer software was the way of implementing the actual outputs for the machine parts

movement before putting it in a prototype manner.

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 ABSTRAK

Mesin lipat pakaian dibangunkan dan direka untuk mengatasi tugas rutin mesin lipatan,

dan kerana keperluan yang sangat diperlukan dalam kehidupan seharian kita. Mesin mewakili

sistem automasi sepenuhnya yang menggabungkan reka bentuk mekanikal dengan reka

bentuk kawalan elektrik. mesin itu dibangunkan untuk melayani orang biasa dengan

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kecerdasan manusia yang normal supaya reka bentuknya benar-benar mewakili cara manual

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pakaian lipat, dan secara khusus mengikuti langkah-langkah lipat lengan belakang lengan

kemudian lipat bahagian baju yang lebih rendah dan akhirnya cuba untuk flip baju ke

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bahagian atasnya dalam perjalanan menyerahkannya kepada pengendali. Baju telah diambil

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sebagai sampel pertama yang mekanisme mesin direka untuk melipat. Kecerdasan manusia

juga diperlukan untuk mengatasi halangan untuk menentukan jenis pakaian dan bentuk. Jadi
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ia dikehendaki oleh pengendali untuk memberi makan pakaian dengan cara tertentu,
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kemudian biarkan mesin melipatnya. Menggunakan simulasi 3D dengan bantuan perisian

kejuruteraan CAD (solidworks) meningkatkan idea-idea awal ke titik yang dikehendaki

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untuk membuang bahagian kawalan. PLC mengambil tempat untuk mengawal mekanisme
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dengan lipat dan urutan masa yang sesuai. Perisian kit model latihan OMRON PLC CP1L

yang disambungkan kepada perisian CX-Programmer adalah cara melaksanakan output

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sebenar untuk pergerakan bahagian mesin sebelum meletakkannya dalam prototaip.

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 ACKNOWLEDGEMENTS

First of all, all praise to Allah who creates us and give us the mind power to recognize

and learn to share and help each other. I am very grateful that Allah offers me this great

chance to learn and continue my study.

I also want to thank my dearest professor Mr. Prof. Ir. Dr. Mahidzal Bin Dahari who gives

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me a huge hand, guiding me all the way along to complete my project report.

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Thirdly, I also want to express my gratitude to all my friends who always support and

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motivate me. Especially Adamu Yusof and Yusof Haroon (Ma Lin). I am really thankful to

you for your pure nice smiles when we shard our true friend’s feelings together.

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Fourthly, I also want to express my deepest appreciation to my four brothers Atheer,
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Hammam, Sohaib, and Ahmed my entire family. Most of all, my parents who are the brightest

star lead me to this very stage. I am really thankful and grateful to them for every single step
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they guide me with their experienced experience for my entire life.

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Last of all, I want to express my deep appreciation to my wife who has more patient than
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anyone else, hiding her illness and tiredness to keep me moving on until I finally reached.
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 Contents
CHAPTER 1 .......................................................................................................................................1
INTRODUCTION ......................................................................................................................1
1.1 Overview ...............................................................................................................................1
1.2 Problem Statement...............................................................................................................2
1.3 Objectives..............................................................................................................................3
1.4 Scope of Study ......................................................................................................................4
1.5 Expected Results ..................................................................................................................4
1.6 Thesis Organization .............................................................................................................5

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CHAPTER 2 .......................................................................................................................................7

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LITERATURE REVIEW ..........................................................................................................7
2.1 Background ...........................................................................................................................7
2.2 Fully Autonomous Clothes Folding ....................................................................................8

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2.3 Semi-Manual Clothes Folding .......................................................................................... 13

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CHAPTER 3 .................................................................................................................................... 16
METHODOLOGY .................................................................................................................. 16
3.1 Introduction ....................................................................................................................... 16
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3.2 Material.............................................................................................................................. 18
3.3 Machine Design ................................................................................................................. 22
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CHAPTER 4 .................................................................................................................................... 47
RESULTS AND DISCUSSION ..................................................................................................... 47
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4.1 Machine Hardware ........................................................................................................... 47

4.2 Ladder Diagram ................................................................................................................ 52
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4.3 Simulation Using OMRON PLC Training Kit ............................................................... 55

CHAPTER 5 .................................................................................................................................... 62
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DISCUSSION AND RECOMMENDATION ....................................................................... 62

5.1 Conclusion ......................................................................................................................... 62
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5.2 Recommendations ............................................................................................................. 63

5.3 What we gain by going through this machine design? .................................................. 63
REFERENCES ................................................................................................................................ 64
Appendix .......................................................................................................................................... 65
Ladder Logic Diagram............................................................................................................ 65

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 LIST OF FIGURES
FIGURE 1. 1 FOLDING STEPS FOR CLOTHES AND DESIRED OUTPUT ......................................................1
FIGURE 1. 2 TWO DIFFERENT FOLDING STEPS FOR FORMAL CLOTHES .................................................2
FIGURE 1. 3 TWO DIFFERENT FOLDING STEPS FOR INFORMAL CLOTHES ..............................................3
FIGURE 1. 4 THE DESIRED WAY FOR THE OPERATOR TO FEED THE DESIGN MACHINE WITH SHIRTS ....3
FIGURE 2. 1 ATTEMPT TO FULLY AUTOMATE CLOTHES FOLDING. (SOURCE;(HUBLI ET AL., 2017)) ....9
FIGURE 2. 3 SEMI-MANUAL FOLDING MACHINE (SOURCE; (MAHAJAN ET AL., 2017)).......................14
FIGURE 3. 1 RESEARCH METHODOLOGY FLOW CHART ......................................................................17

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FIGURE 3. 2 MAIN SOLIDWORKS ICONS .............................................................................................18

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FIGURE 3. 3 OMRON KIT DIMENSIONS AND SHAPE ..........................................................................19
FIGURE 3.4 CX-PROGRAMMER SOFTWARE .......................................................................................20
FIGURE 3. 5 CX-PROGRAMMER MAIN WORKING SPACES ..................................................................22

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FIGURE 3. 6 MAIN FOLDING BOARDS ................................................................................................23

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FIGURE 3. 7 DRIVE GEAR ...................................................................................................................23
FIGURE 3. 8 DRIVEN GEAR .................................................................................................................24
FIGURE 3. 9 STEPPER MOTOR ASSEMBLY ...........................................................................................25
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FIGURE 3. 10 HINGE ...........................................................................................................................26
FIGURE 3. 11 LEFT VIEW ....................................................................................................................27
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FIGURE 3. 12 ISOMETRIC VIEW ..........................................................................................................27

FIGURE 3. 13 FIRST AND FINAL MECHANISM POSITION ....................................................................29
FIGURE 3. 14 MACHINE MECHANISM (A) SHOWS THE DIMENSIONS BETWEEN THE CONTACT POINT OF
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THE PARTS. (B) THE MECHANISM REAL SHAPE. ..........................................................................31

FIGURE 3. 15 FORCE ANALYSIS FOR THE MOVING MECHANISM .........................................................32

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FIGURE 3. 16 INITIAL AND FINAL POSITIONS .....................................................................................35

FIGURE 3. 17 KINETICS ANALYSIS FOR THE DC MOTOR ....................................................................38
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FIGURE 3. 18 SEQUENCE DIAGRAM FOR THE MACHINE LOGIC ...........................................................42

FIGURE 3. 19 LADDER LOGIC DIAGRAM FOR THE MACHINE LOGIC ....................................................42
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FIGURE 3.19 LADDER LOGIC DIAGRAM FOR THE MACHINE LOGIC (CONTINUED) ..............................43
FIGURE 3. 20 STEPPER MOTOR DRIVERS A) STP-DRV-DLO5. B) M542. C) TB6600. .......................44
FIGURE 3. 21 IMPLEMENTATION OF DRIVERS WIRING ........................................................................45
FIGURE 3. 22 TYPICAL CONNECTION FOR THE DRIVER STP-DRV-DLO5 WITH THE PLC .................46
FIGURE 4. 1 TOP AND FRONT VIEW FOR THE MACHINE WITH SOME DIMENSIONS .............................47
FIGURE 4. 2 ISOMETRIC VIEW WITH THE RIGHT VIEW SHOWS HIDDEN LINE. .....................................48
FIGURE 4. 3 EXPLODED VIEW FOR CLOTHES FOLDING MACHINE WITH ANNOTATIONS......................49

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FIGURE 4. 4 FOLDING MACHINE IN ACTION (A) LEFT BOARD IN ACTION. (B) RIGHT BOARD IN ACTION.
(C) MIDDLE BOARD IN ACTION....................................................................................................51
FIGURE 4. 5 CONDITION OF OMRON PLC BEFORE SIMULATION STARTED.......................................52
FIGURE 4. 6 LADDER LOGIC DIAGRAM ACTIVATION (A) PHYSICAL INPUTS RESPONSIBLE FOR HIGH
OUTPUT (B) LATCH 100.10 IS KEEPING THE OUTPUT HIGH. ........................................................53

FIGURE 4. 7 THE LOGIC SEQUENCE OF BACKWARD ROTATION FOR MOTOR 1....................................54

FIGURE 4. 8 THE LOGIC SEQUENCE OF FORWARD ROTATION FOR MOTOR 2 ......................................54
FIGURE 4. 9 THE LOGIC SEQUENCE OF BACKWARD ROTATION FOR MOTOR 2....................................54
FIGURE 4. 10 LADDER DIAGRAM WHILE ACTIVATING THE CONVEYOR DC MOTORS .........................55

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FIGURE 4. 11 OMRON PLC ON STANDBY CONDITION ........................................................................55

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FIGURE 4. 12 THE FIRST MOTOR RECEIVES THE SIGNAL AND RUNNING .............................................56
FIGURE 4. 13 HOLDING RELAY LATCH KEEPS THE SYSTEM ON .........................................................56
FIGURE 4. 14 THE FIRST MOTOR RECEIVES THE SIGNAL AND RUNNING .............................................57

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FIGURE 4. 15 THE SECOND MOTOR RECEIVES THE SIGNAL AND RUNNING FORWARD .......................57

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FIGURE 4. 16 THE SECOND MOTOR RECEIVES THE SIGNAL AND RUNNING BACKWARD .....................58
FIGURE 4. 17 THE THIRD MOTOR RECEIVES THE SIGNAL AND RUNNING FORWARD...........................58
FIGURE 4. 18 THE THIRD MOTOR RECEIVES THE SIGNAL AND RUNNING BACKWARD ........................59
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FIGURE 4. 19 INDICATORS ARE ON AS DC MOTORS ARE IN ACTION...................................................59
FIGURE 4. 20 SWITCH 2 ACTIVATED TO STOP THE SYSTEM FROM RUNNING ......................................60
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FIGURE 4. 21 SECOND DC MOTOR STILL ON WHILE THE FIRST ONE IS OFF. .......................................60
FIGURE 4. 22 FINAL SHAPE OF FOLDED CLOTH, DELIVERED BY THE MACHINE. .................................61
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FIGURE5. 1 FINAL SHAPE OF FOLDED CLOTH, DELIVERED BY THE MACHINE. ...................................62

APPENDIX A1. 1 LADDER LOGIC DIAGRAM .......................................................................................65
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APPENDIX A1. 1 LADDER LOGIC DIAGRAM .......................................................................................66

APPENDIX A1. 1 LADDER LOGIC DIAGRAM .......................................................................................66
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 LIST OF TABLES

TABLE 3. 1 SPECIFICATION OF OMRON PLC (CP1L) ...................................................................... 19

TABLE 3. 2 BILL OF MATERIAL FOR THE MACHINE ........................................................................... 28
TABLE 3. 3 MACHINE MECHANISM PARTS (MASS, MOMENT OF INERTIA) ....................................... 30
TABLE 3. 4 BOOLEAN EQUATION FOR THE MACHINE LOGIC............................................................. 40
TABLE 3. 5 CONNECTION CONFIGURATION FOR THE STEPPER MOTOR DRIVER ................................ 45
TABLE 3. 6 STEPPER MOTOR DRIVER ELECTRICAL SPECIFICATION ................................................... 45
TABLE 3. 7 STEPPER MOTOR DRIVER SIGNALS ACTIVATION TABLE .................................................. 46

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TABLE 4. 1 FOLDING MACHINE PARTS WITH REF. ANNOTATION NUMBER TO THE EXPLODED VIEW IN

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FIGURE 4.3 ................................................................................................................................. 50

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 CHAPTER 1
INTRODUCTION

1.1 Overview

Folding your clothes is one of the most boring and routine task that you will ever do again

and again. So developing a machine that overcome this boring issue was the aim of this

research. Clothes are classified into many groups every group has its own specification and

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dimensions. These groups are (Shirts, Trousers, Shorts, Socks, Jackets, Suits and Formal

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Beadles). Every category of this group has also its own sub-group with different size and

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dimensions. So because of this wide variety of groups and sub-groups we face the first

obstacle in our mission of designing the machine. Hence we decided to select one group of

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these groups and focus only on one sub-group of them. we go also only with one way of
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folding for this shape of clothes. Because of the wide difference in the clothes folding ways

between cultures and even single peoples in the same society. Our selection was under shirts
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group and to be more specify by selecting the formal and the informal ones. Automated the
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manual folding steps shown in the Figure 1.1 is the goal of this research.
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Figure 1. 1 Folding steps for clothes and desired output

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1.2 Problem Statement

Since we roam with a very huge numbers of clothes groups and types, and even after we

select our sub-group that we will take as an example to start our folding machine, we still

face a problem of which way of folding we have to start our initial design with. To understand

the different ways of clothes folding. figure 1.2 shows a different folding methods for a

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formal shirt, while figure1.3 shows another difference in folding the informal shirts which

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people use around the world.

One of the main obstacles is how the clothes will be feed to the machine? Can we just drop

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them inside it as in the washing machine? or we have still to use the human intelligence and

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feed the machine with the clothes in a proper way?
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We considered here the easy way for our research, so the operator has to feed the machine

with the shirts with a proper define way. Shirts has to be flipped and expanded on the machine
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as shown if figure 1.4. if we try to drop the clothes inside the machine and give the machine

the chance to identify the type clothes or the shape. Machine has to have the ability of image
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processing and artificial intelligence for the processing of the shape. And this will lead our
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research project to deal with more complicated issue and to be more complex and advanced.
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Figure 1. 2 Two different folding steps for formal clothes

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 Figure 1. 3 Two different folding steps for informal clothes

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Figure 1. 4 The desired way for the operator to feed the design machine with shirts
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1.3 Objectives
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The goal of this research is to improve and design a complete integrated automation system
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of mechanical parts and assembly with a programmable logic controller (PLC), implemented

in clothes folding machine. The objectives of this research are:

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a. To be more familiar with automation systems by combining electrical (low voltage)

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system, with the mechanical system that integrates the mechanical parts to achieve

the proper action.

b. Develop and design clothes folding machine with proper sequence to fulfill the
client requirement, these sequences are:
1- Define the mechanism motion with proper machinery parts.
2- Specify the motors torque and speed.
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 3- Specify the Motors drivers and wiring diagram.
4- Build the sequence diagram for the motion.
5- Build the ladder diagram with a suitable software complies with the PLC.
c. Improve the skills of using the programmable logic controller and how to connect it
with the stepper motors.

1.4 Scope of Study

This research is trying to build a smart automation system that uses the advanced industrial

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parts and engineering softwares. By using the OMRON PLC training kit and the solidworks

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3D design we will build the clothes folding machine and try to simulate it for our initial

prototype.

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Hence The clothes folding machine represented an automation system, it has to include the

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machinery design and the mechanisms interface with the low voltage control units that
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represented by the CP1L PLC as a logic, stepper motor and dc motors as an actuator, with

the proximity switch as a sensor.

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So, for the machinery parts the following conditions has to be applied to achieve a proper
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machine motion:
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a- Machine parts has to be design and build with proper dimensions. (actual logical
size, weight and material type).
b- Machine parts has to interfere and connected to achieve the initial and final position
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without any jerk and material worn out.

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c- Plc should be programmed and interface with the stepper motor driver perfectly.
d- System should be tested and stopped with a proper button accessed by the operators.
1.5 Expected Results

By completing this research, the expected goal is to build a very defined automated system

that synchronize between the mechanical part and electrical one without any serious fail or

damages. This machine can be carried out and be built as a prototype initially so once other

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problems appears we can manage and solve them or even any more special improvement can

be done to achieve an excellent automation system.

1.6 Thesis Organization

In chapter 1, it presents the whole idea about starting an automating system and gives an

overview for the variety of clothes that we are intending to design the machine for. Then the

main objectives with the scope of work and describe shortly some obstacles that the designer

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had faces.

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In chapter 2, here we pass through different ways of how human can automate the folding

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task, by using robot arms or by using mechanical interaction by using motor control. People

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still trying to improve the task more and more depending on other experience or initiating

their own prototypes.

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In chapter 3, An important skill of a design engineer is to know how to integrate systems and

combine them together to ensure the full proper task with a high efficiency during operation.
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Here we go through the mechanical system applying the kinematic analysis and machinery
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design to define the initial and final position of the moving parts. Using the powerful
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engineering tools and software such as SOLIDWORKS and OMRON PLC programmer, the

clothes folding machine will be design, simulated and tested. Since the physical model is not
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going to be built, the programming can be done several times so that the challenges faced
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with a hardware can be reduced or oven fully eliminated.

In chapter 4, results and the total system output are explained and discussed separately,

starting by the machine steps, folding board’s action after the motor action. Then the ladder

diagram outputs in steps and how it appears after doing online simulation with the CX-

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program. Finally, the PLC outputs which are the led indicators in the actual relay outputs.

Every led present a motor certain action.

In chapter 5, we present the research conclusion with some recommendations to improve the

system, it was essential to know the weakness points of the system to avoid and overcome

them while building the machine for manufacturing.

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 CHAPTER 2
LITERATURE REVIEW

2.1 Background

From the 20th century and beyond, machines have made human life much easier by taking

over most of the tedious and repetitive tasks. Humans now have more time to attend to other

pressing issues. One of the areas where machines have benefitted mankind is in the laundry

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services. All over the globe, different forms of sophisticated machines are available for doing

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the laundries. While some perform only the washing leaving the drying to human to perform

manually, others are so sophisticated that they can carry out both the washing and drying.

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However, even with this sophistication, the laundry task is yet to be fully complete as the

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washed clothes need to be neatly folded before they are stored. Most of the machines are

handicapped when it comes to autonomous folding of the clothes as they are only capable of
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washing and drying. To complete the laundry task, different approaches have been made by
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researchers to come up with models, designs, and machines that can perform the folding task.

In this chapter, some of the works done on the clothes folding machine will be investigated.
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In this research project folding of clothes will be categorized into three kinds depending on
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the level of technology. First is the manual folding which is done by hand. It is the oldest and

most efficient method till date. The second kind is the semi-manual method where the clothes
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are being laid on a platform and then the folding is done by the machine. So, it involves
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human for spreading and laying the clothes on the platform, then the motor-controlled

platform then carries out the folding. The final and the third type is the fully automated kind

of folding. Here the clothes are being fully folded by an intelligent folding machine. For the

fully automated folding, the clothes are spread out, laid, and folded all automatically by a

machine. This is mostly carried out by two-armed robot equipped with cameras or range

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finders for image detection and dexterous grippers for manipulations. This third kind of

folding clothes is still under serious research as a total breakthrough has not been made in

this regard.

2.2 Fully Autonomous Clothes Folding

It has been stated and worthy of notice that a cloth is deformable, flexible and non-rigid in

shape which makes it very difficult to manipulate (Miller et al., 2015). This complexity has

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been the major barrier hindering the full development of the clothes folding machine. Sitting

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on some assumptions, (Miller et al., 2015) have come up with some cloth configurations

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which could be represented by some parameters that are polygonal in nature. They used a

Willow Garage PR2 robot to test their model which is an algorithm that outputs the motion

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plans for executing a particular kind of fold. Naming it g-folds which stands for gravity folds,
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they used four categories of clothing for their model: short sleeve shirts, long sleeve shirts,

pants, and towels. Each of these categories is represented by a polygon. Their work can be
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classified under the third kind of clothes folding method as they have tried to carry out a fully

automated means of folding clothes. A similar work which is aimed at addressing clothes
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perception and manipulation (CloPeMa) has been conducted in (Stria et al., 2014) where a
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dual robot was used instead of a Willow garage PR2. Their research which also deals with a

polygonal model is an extension and an improvement over previous polygonal model works.
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The novelty in their study is that a new garment polygonal model was developed alongside
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its manipulation planning algorithm. There results showed that the process of CloPeMa can

be sped up by two orders of magnitude. In another article, a system which folds clothing from

a random crumpled state to a fine state is presented in (Bersch, Pitzer, & Kammel, 2011).

They developed an algorithm which has a novel detection and grasp strategy which is capable

of suggesting grasp points from poses of the clothing. The drawback of this system is that it

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is limited to t-shirts alone as shown by the experiments that have been conducted in their

work. They also made use of the Willow Garage PR 2 for their experiments. A set of

procedure was including pick-up, perception, estimation of current grasp point, selection of

next grasp point, grasp pose computation and evaluation, grasp execution, grasp verification,

and finally folding (Bersch et al., 2011). The major focus of their work on the grasp points.

With the use of fiducial markers, the configuration of the t-shirt need not be known, thereby

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making their system tolerant to all kinds of t-shirts. In a similar paper, an algorithm that can

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reliably detect the corners of the piece of cloth was developed (Maitin-Shepard, Cusumano-

Towner, Lei, & Abbeel, 2010). They based their algorithm on geometric cues due to its

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robustness in texture variation. Rather than using t-shirts for their experiments, they based

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their experiments on a towel. However, they concluded that their algorithm can be applied to

other kinds of clothing. Willow Garage PR 2 has been used in their research just like in the
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two previously mentioned papers. Figure 2.1 shows the process of folding using the willow
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garage PR 2 robot.
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Figure 2. 1 Attempt to fully automate clothes folding. (source;(Hubli et al., 2017))

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An all-encompassing work on autonomous folding machine has been conducted where all

the process of clothes folding from the sorting of the clothes from pile of clothing to

unfolding, to spreading and finally folding is taken care of (Doumanoglou et al., 2016).

Capitalizing on the fact that clothes are deformable which makes perception and

manipulation difficult, a two-arm robot was used in their research. All the subtasks necessary

for an autonomous clothes folding has been addressed in their work making it the first of its

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kind. What makes their work unique is the fact that they proposed a novel method for

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completely unfolding a partially unfolded garment. Some garments tend to fold up at the

edges after attempts have been made to spread them out, so this novel approach takes care of

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such problems. This was achieved by comparing the deformation of the examined garment

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with the template garment for a particular kind of clothing (e.g t-shirt). Another novelty in

their research is the area of garment unfolding which is based on classic random forests. They
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called their novel method active random forests which performs a good classification and
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regression, thus selecting the best viewpoint. From their experiments, they have concluded

that their work is not only limited to t-shirts but can also be applied to all forms or kinds of
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garment.
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To fully automate the laundry process, classification is a key property that a system should

have as that will enable the system to autonomously perform washing, drying, and folding.
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(Willimon, Birchfield, & Walker, 2011) worked on classification of clothing using an

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interactive perception technique. Two tasks are involved in this technique, the first being the

isolation of clothing from a pile one after another, and the second task being classification of

the sorted clothing into pre-specified categories (short sleeves, long sleeves, pants, shorts,

and underwear) using the information form the visual based shape and appearance.

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It has been stated that clothes are generally difficult to handle due to their flexibility, but

linen is even more difficult to handle. So, for proper and efficient handling at a linen supply

industry, (Hata, Hojoh, Toda, & Hamada, 2011) developed a system that can autonomously

input washed clothes (linen based) into washing and folding machines. Also using towels for

testing their algorithm, they have agreed with those who believe that the most essential part

to handle a rectangular piece of clothing is at the edges. The number of steps in the algorithm

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of (Hata et al., 2011) is five (5) which is contrary to the number of steps in (Willimon et al.,

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2011).

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Utilizing small mobile robots and a normal table, (Watanabe, Kawamura, Iizuka, & Suzuki,

2107) proposed a system which is capable of folding clothes. Although they were faced with

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limited work space, they were able to implement their algorithm. The mobile robots are
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equipped with markers which are used to obtain coordinates and also manipulate the clothes

while an external camera is mounted above the robots to fetch RGB images files for the PC.
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Their system uses a path planning algorithm to trace the coordinates needed to fold the

clothes. In another study (Yang et al., 2017), a humanoid robot is programmed using deep
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learning to perform the herculean task of folding a soft object. Cotton material was used as
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the training and testing data set.

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An attempt at attaining a full autonomous clothes folding has been made in the work of (Hubli
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et al., 2017) where a three stage procedure is used to get a clothes from a pile transformed

into a neat uniform folds. A gripper capable of sliding was employed in separating each

clothe from the pile of clothes. With the aid of fans and moveable grippers, the second step

of unfurling the clothes is achieved thereby spreading the clothes over the platform for

folding. An orientation algorithm which is angular-based is used to compare the actual

orientation with that of the template in order to achieve the best orientation of the unfurled
11
clothes. (Hubli et al., 2017) concluded that although their model is not void of some

inaccuracies, they have been able to automate the clothes folding process. Not precise form

of measurement was seen present in their work. So, further investigation is needed to

optimize their work. In a similar study, (Hamada, Hata, Hojoh, Kobayashi, & Fukumoto,

2009) made use of two robot arms to perform the folding task on linen. Although they didn’t

develop any serious algorithm, trial and error method was adopted by them to perform several

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hundreds of experiments. They also divided the task into three stages as described previously.

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(Hamada et al., 2009) relied on images obtained from the cameras mounted on robots and

made their robot perform grasping of corners and edges for the manipulation and eventually

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folding.

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Figure 2. 2 Attempt to fully automate clothes folding. (source;(Hubli et al., 2017))

By generating a folding path, a single arm robot was used to perform garment folding in the
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work of (Petrík, Smutný, Krsek, & Hlavác, 2017). Their research was based on the static
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equilibrium of forces and a two-dimensional shape were used to model the garment as an

elastic shell. This makes the work an upgraded version of a previous similar one-dimensional

path generation technique. Their model has the advantage of preventing slippage of the

garment while it is being folded on a surface with low friction. One of the limitations in

(Petrík et al., 2017) is the fact that material properties detection is somewhat left for the

12
operator to be manually done. By making use of some complex algorithms which collects

data form 3D images and then converting them into grayscale image, (Estevez, Victores,

Morante, & Balaguer, 2016) investigated how clothes can be unfolded. In their model, height

of contours are used to generate a height profile which the systems records as folded or

unfolded part. For contours that are high, the model takes them a critically folded part, while

for low contours the model takes them as unfolded parts.

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2.3 Semi-Manual Clothes Folding

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For the semi-manual kind of clothes folding method, the work of (Mahajan, Prasad, Binnar,

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& Tambe, 2017) has shown some advancement in this regard. A motor driven clothes folding

machine was developed in their project. They aimed at reducing the time consumed during

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the house chores (laundry in particular) thereby saving time for other chores. The project
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consisting of folding trays, folding flaps, and flips was focused on folding only t-shirts. Just

like in the work of (Bersch et al., 2011), the shortcoming of this project is the fact that it
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cannot accommodate all types of garments as all the system is limited to t-shirts only. It is

believed that if applied in the Indian textile industry, it will save plenty of time and minimize
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errors in sorting of textiles. Figure 2.2 shows the work of (Bersch et al., 2011).
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 Figure 2. 3 Semi-manual folding machine (source; (Mahajan et al., 2017))

In an effort to eliminate the manual laying of the clothes on the semi-manual folding machine,

(Miyamotoa, Mub, & Kitazono, 2014) developed a clothes folding machine which is an

enhancement of the previous work of (Mahajan et al., 2017). This is because their folding

machine is able to fold clothes (t-shirt) from the state of hanging. The machine is also

equipped with sensors which detects whether or not the clothes are wet before folding, and a

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special kind of hanger which folds up during the clothes folding process. Inexpensive

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materials were used in the work of (Miyamotoa et al., 2014) as the folding board is made of

cardboard, while the frames are made of aluminum. The motors used to control the folding

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motion are off-the-shelf (OTS) servo motors.

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Figure 2. 4 Folding of clothes from hanging (source; (Miyamotoa et al., 2014))

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While most of the articles used in this project did their works on clothes folding, the article
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of (Triantafyllou, Mariolis, Kargakos, Malassiotis, & Aspragathos, 2016) rather focuses on

unfolding of clothes. Relying on some heuristic approaches, (Triantafyllou et al., 2016) also

adopted the detection and manipulation method to determine two arbitrary grasping points

on a garment where when held, the clothe unfolds using gravity. A two-arm robot equipped

with range sensors for image detection was used in their work. They concluded that the

14
geometric approach they have used in their method is more advantageous than the machine

learning method based on some reasons.

In summary, different articles on clothes folding have been reviewed. While some of the

researches are working on full automation of the clothes folding, others have attempted a

semi-automatic folding. In all of the researches, emphases were made on the usage of robots

to accomplish the folding task. Most of them involved algorithms that are used for the

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detection and manipulation of the clothes. However, little or no effort has been made to utilize

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a PLC for the programming aspect of the clothes folding. So, in this research project, a PLC

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based kind of programming will be used in controlling the clothes folding machine. The

research project is limited to the folding of the clothe only. The detection and spreading of

the clothes is not treated in this project.

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15
 CHAPTER 3
METHODOLOGY

Herein we are going to explain all the steps and the methodologies we used to establish and

improve our prototype simulation for the Clothes Folding Machine using the engineering

software’s (Solidworks and OMRON PLC).

3.1 Introduction

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In this chapter, the steps and the methodologies that were used to establish and improve the

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prototype are discussed. The simulation and analysis of the Clothes Folding Machine were

achieved using the engineering software Solidworks for the design and OMRON

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Programmable Logic Controller (PLC) for the simulation.

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The first step in conducting this project was to put down the sketches of the initial ideas of
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the machine prototype on paper. Upon satisfactory sketches, 3D design is performed using a

CAD software, SOLIDWORKS was used in this regard. All these steps and more are
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represented in the flow chart of the research methodology given in Figure 3.1.
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 Start

Conduct thorough literature review

Design individual parts using appropriate software (Solidworks)

Generate the full assembly

Kinematics Analysis

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Motors and drivers Selection

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Design the ladder logic program

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Test the program
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Is program
ok?
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Experiments and results

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Discussion and Conclusions

End

Figure 3. 1 Research methodology flow chart

17
3.2 Material

3.2.1 Solidworks Software

Solidworks is one of the powerful softwares that helps the engineers to imagine and visualize

their designs and ideas in a powerful manner. It gives the designer the ability to present his

ideas in a 3D model and in assemblies. By using SOLIDWORKS, a designer is able to mate

different parts together and create sub-assemblies. These sub-assemblies are assembled

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together to generate a full assembly of the machine parts.

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Running the software will be by clicking the main icons of mechanical desing in the computer

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system. Figure 3.2 below shows the main software icons that engineers can use.

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Figure 3. 2 Main Solidworks Icons

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3.2.2 OMRON Programmable Logic Contoller CP1L

OMRON Corpration manufacture provides Programmable Logic Controller with different

kit specifications, here we are using the training kit model CP1L that has built in pulse, serial

communications and digital input/output.

The kit has the ability to contorl small and medium machine size, this CP1L has an embedded

ether net port that gives more flexibility in funcitioning, logging and monitoring. Since we

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are dealling with stepper motor in our desgin also the CP1L has a high-precision position

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contol. Figure 3.3 shows the physical shape of the OMRON PLC CP1L.

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Figure 3. 3 OMRON Kit dimensions and shape

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Using the PLC in a proper way will be by having all the information about its spcifications

and charachteristics, for OMRON PLC Training Kit table 3.1 shows the specifications.
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Table 3. 1 Specification of OMRON PLC (CP1L)

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 Type AC power supply models

Model CP1L

Power Supply 100 to 240 VAC 50/60 Hz

Operating voltage range 85 to 264 VAC

Power consumption 30 VA max

Inrush current 100 to 120 VAC inputs:

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20 A max. ( at room Temerature ),8 ms max.

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200 to 240 VAC inputs:

40 A max. ( at room temperature ), 8 ms max.

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External power supply 2000 mA at 24 VDC

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Insulation resistance 20 MΩ min. ( at 500 VDC) between the external AC

terminals and GR terminals.

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Dielectric strength 2.300 VAC at 50/60 Hz for 1 min between the external AC

and GR terminals, Leakage current: 5 mA max.

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Noise immunity Confirms to IEC 61000-4-4.2 KV ( power supply line ).

Vibration resistance Conforms to JIS C60068-2-6. 10 to 57 Hz,0.075-mm

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amplitude, 57 to 150 Hz, acceleration: 9.8 𝑚𝑚�𝑠𝑠 2 in X,Y and

Z directions for 80 minutes each.

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Shock resistance Conforms to JIS C60068-2-27. 147 𝑚𝑚�𝑠𝑠 2 three times each
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in X,Y and Z direction.

Ambient operating termprature 0𝑜𝑜 to 55𝑜𝑜 C

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Ambient humidity 10% to 90% ( no condensation )

Ambient operating environment No corrosive gas

Ambient storage temperature -20% - 75𝑜𝑜 C ( excluding battery ).

Power holding time 10 ms min.

3.2.3 CX-Programmer Software

20
CX-programmer which main icon is shown in figure 3.4 is a software used to constuct the

logic program for the OMRON PLC. This software is one of the software included in the

CX-ONE package provided by the manufacturer togither with OMRON PLC.

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Figure 3. 4 CX-Programmer

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CX-Programmer software uses ladder logic program to communicate the information to PLC.

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The users can choose the OMRON PLC mode ( programming, running, online runinig) to

design their program and check it, even OMRON PLC give the chance to the designer to
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simulate the program using online simulator provided in the sofware. This is to ensure that

the program functions according to requirement before it is uploaded to real PLC.

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The first window that you see when starting CX-Programmer is the main application window.
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This window is the launching point for you to access other CX-Programmer views and
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functions. The screen will be blank until you open or create a project. When a project has

been opened or created, you will see two main working spaces and additional menu options
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appear:
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• Project (Information) Workspace

Located on the left for accessing the information about the PLCs and programs used
in the project.

• Ladder/Programming Workspace

Located on the right for creating the PLC programs.

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Figure 3.5 shows the main working space for the CX-Program.

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Figure 3. 5 CX-Programmer Main working spaces

3.3 Machine Design

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Since our goal is to find a machine that is capable to fold the clothes, it was necessary to go
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through the major steps of designing ( Sketching, Improving the drawing to 3D, Doing the
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motion study (simulating), analyzing, and building the initial prototype). In the following

sub-section we will explain these steps.

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3.3.1. Major Parts

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In this section we are going to show the major parts dimensions and specification individually

before we create our assembly .

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3.3.1.1. Main folding boards

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Figure 3. 6 Main Folding Boards

3.3.1.2 Drive Gear

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Figure 3. 7 Drive Gear

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3.3.1.3 Driven Gear

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Figure 3. 8 Driven Gear
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3.3.1.4 Stepper motor

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Figure 3. 9 Stepper motor assembly

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3.3.1.5 Hinge

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Figure 3. 10 Hinge
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3.3.2 Full Machine Assembly

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Figure 3. 11 Left View
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Figure 3. 12 Isometric View

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Table 3. 2 Bill of Material for the machine

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3.3.2.1 Position view

Figure 3.13 shows the mechanism move for the clothes folding machine, we can see the

implementation for each part mentioned before as a line and the points of connection between

these linkages.

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Figure 3. 13 First and Final Mechanism Position

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3.3.3 Motor Selection:

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To specify the accurate engineering data for the motor, we have to define the characteristics

for the motor (Torque, Pulses / revolution, rising and falling time). All of these characteristics

can be calculated as per motion requirement and system mechanism movement.

29
 3.3.3.1 Stepper motor:

Stepper motor is one of the most popular motors used to achieve an exact position with a

high resolution and precision.in this section we will find the characteristics (Torque,

Pulses/revolution, rising and falling time) of the stepper motor that we used to actuate our

mechanical mechanisms.

3.3.3.1.1 Finding the Motor Torque:

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The stepper motor torque is divided into two types of torque, the acceleration torque, and the

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running torque. The acceleration torque is related to the system inertia and system

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acceleration, the running torque is due to friction and oppose forces need to overcome them.

𝑇𝑇 = 𝑇𝑇𝑎𝑎𝑎𝑎𝑎𝑎 + 𝑇𝑇 𝑟𝑟𝑟𝑟𝑟𝑟 …………………………………………………………………. (3.1)

𝑇𝑇𝑎𝑎𝑎𝑎𝑎𝑎 = 𝐽𝐽 ∗ 𝛼𝛼 ……………………………………………………………………… (3.2)

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𝑇𝑇𝑟𝑟𝑟𝑟𝑟𝑟 = 𝐹𝐹 ∗ 𝑑𝑑 ……………………………………………………………………… (3.3)

𝐽𝐽 = 𝐽𝐽𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 + 𝐽𝐽𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 + �𝐽𝐽𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙 + 𝐽𝐽ℎ𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 + 𝐽𝐽𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 � ………………………….. (3.4)

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Table 3. 3 Machine mechanism parts (Mass, Moment of Inertia)

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Item Part Material/Mass J (moment of inertia around J ( moment of inertia

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# Description (grams) output axis) gram.mm^2 around moving axis)

gram.mm^2
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1 Drive Gear Brass/425 173929.7 173929.7

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2 Driven Gear Brass/3840 11773104.3 11773104.3

3 Linkage Alloy 1060/55 1757444.3 14086574.5

4 Holing pad Alloy 1060/52 34995.4

5 Wooden board Oak wood/560 12505000.0

Total Moment of inertia 43252615.8

30
Since we are designing the system, We assumed the acceleration to be
𝜋𝜋 𝑟𝑟𝑟𝑟𝑟𝑟� . This
2 𝑠𝑠 2

assumption was concluded as we required the wooden board to travel from its initial position

the final one by 1 second.

Recall equation (2) and substitute the values of J mentioned in table 3.3 and the assumed α

we can get the following torque value in N.M

𝜋𝜋
� 𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔. 𝑚𝑚𝑚𝑚2 ∗ 𝑟𝑟𝑟𝑟𝑟𝑟�𝑠𝑠 2 �

a
𝑇𝑇𝑎𝑎𝑎𝑎𝑎𝑎 = 43252615.8 ∗
2

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𝑇𝑇𝑎𝑎𝑎𝑎𝑎𝑎 = 67906606.8 ∗ 10−9 � 𝑘𝑘𝑘𝑘. 𝑚𝑚2 ∗ 𝑟𝑟𝑟𝑟𝑟𝑟�𝑠𝑠 2 �

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𝑻𝑻𝒂𝒂𝒂𝒂𝒂𝒂 = 𝟎𝟎. 𝟎𝟎𝟎𝟎𝟎𝟎 𝑵𝑵. 𝑴𝑴

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For the running torque we are required to find the effected forces for the system that acts on
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point B for the Driven Gear. Figure 3.14 shows the full mechanism parts, (a) shows the

dimensions between the contact point of the parts. (b) the mechanism real shape.
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N
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W1
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Figure 3. 14 Machine mechanism (a) shows the dimensions between the contact point of the parts.
(b) the mechanism real shape.

31
Recalling the equation (3)

𝑇𝑇𝑟𝑟𝑟𝑟𝑟𝑟 = 𝐹𝐹 ∗ 𝑑𝑑

Using Newton’s Second Law (NSL)

N
Cloth = 300 N

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∑ 𝐹𝐹𝑦𝑦 = 0

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𝑁𝑁 − 𝑊𝑊1 = 0 W1

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where 𝑁𝑁 is the normal force from the plate and

𝑊𝑊1 is the cloth’s weight, accordingly:

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𝑁𝑁 = 2.943 𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁 135mm
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Wooden plate = 560 N

100mm
A
∑ 𝐹𝐹𝑦𝑦 = 0 R F1 W2
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𝑅𝑅 + 𝐹𝐹1 − 𝑁𝑁 − 𝑊𝑊2 = 0
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Figure 3. 15 Force analysis for the moving mechanism

where 𝑅𝑅 is the reaction force on the hinge

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𝐹𝐹1 Normal force from the Pushing hinge and

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𝑊𝑊2 is the plate’s weight, accordingly:

𝑅𝑅 + 𝐹𝐹1 = 8.4366

∑ 𝑀𝑀𝐴𝐴 = 0

0.035 ∗ 𝐹𝐹1 + 0.135 ∗ 𝑅𝑅 = 0

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Solving the previous two equations lead to:

𝑅𝑅 = −2.95281 𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁, 𝐹𝐹1 = 11.38941 𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁

Pushing hinge = 54 N F1

∑ 𝐹𝐹𝑦𝑦 = 0

𝐹𝐹2 − 𝑊𝑊3 − 𝐹𝐹1 = 0

a
where 𝐹𝐹2 is the reaction force from the link, F2 W3

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𝑊𝑊3 is the Pushing hinge weight and

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𝐹𝐹1 is the resultant force from plate and cloth, then: F2

𝐹𝐹2 = 11.91915 𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁

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Linkage Arm = 52 N
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∑ 𝐹𝐹𝑦𝑦 = 0

𝐹𝐹3 − 𝑊𝑊4 − 𝐹𝐹2 = 0

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where 𝐹𝐹2 is the resultant force from upper parts i.e. Cloth, plate and Pushing hinge
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F3

𝑊𝑊4 is the link’s weight and

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𝐹𝐹3 is the reaction force from the gear, then:

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𝐹𝐹3 = 12.42927 𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁 Center point C for the driven gear

For the gears meshing, we finalize the forces as follows:

∑ 𝑀𝑀𝐵𝐵 = 0
Center point B for the driven gear
0.098 ∗ 𝐹𝐹3 − 0.11 ∗ 𝐹𝐹𝑡𝑡 = 0
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where, 𝐹𝐹3 is the resultant force from upper parts

𝐹𝐹𝑡𝑡 , 𝐹𝐹𝑟𝑟 are the tangential and redial forces, respectively.

Solving this equation lead to:

Fr
𝐹𝐹𝑡𝑡 = 11.07334964 𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁 F3
Ry

∑ 𝑀𝑀𝑐𝑐 = 0 Rx
Ft

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𝑇𝑇 − 0.037 ∗ 𝐹𝐹𝑡𝑡 = 0

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Solving this equation lead to: B

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𝑇𝑇 = 0.4097139 𝑁𝑁. 𝑚𝑚

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So now by adding the two torques together Ft

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we will get the total motor torque
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𝑇𝑇 = 𝑇𝑇𝑎𝑎𝑎𝑎𝑎𝑎 + 𝑇𝑇 𝑟𝑟𝑟𝑟𝑟𝑟 c Fr

𝑇𝑇 = 0.068 + 0.41 = 0.48 𝑁𝑁. 𝑀𝑀

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3.3.3.1.2. Find the Pulses for the Motor per one Full Move .
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To calculate the minimum pulses for the motor to get the desired output, we have to analyze
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the mechanism machinary and to define the angle required by the drive motor, in addtion to

the pulses of the rising and falling time.

So by looking to the side view of the system we find that the diven Gear ( 88 teeth) is

travilling a 800 angle to reach the desired output postion. By converting this angle to a

travilling distance on the parameter of the driven gear and reflected it to the drive Gear ( 30

34
 teeth) we can find the travilling angle for the motor shaft and then calculate the pulses

required.

Ө1 𝑟𝑟2
=
Ө2 𝑟𝑟1

𝑟𝑟2
Ө1 = ∗ Ө2
𝑟𝑟1

0. 11𝑚𝑚𝑚𝑚

a
Ө1 = ∗ 1.4𝑟𝑟𝑟𝑟𝑟𝑟
0.037𝑚𝑚𝑚𝑚

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Ө1 = 4.16 𝑟𝑟𝑟𝑟𝑟𝑟−→ 238.5 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑

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Where

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r2, r1 , Ө2 , Ө1 are driven gear raduis, drive gear raduis, driven gear travilling angle , drive gear travilling angle respectively
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Ө𝟐𝟐 𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 80 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑

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Figure 3. 16 Initial and Final positions

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By selecting a 1.8𝑜𝑜 stepper motor, and with 239 steps required to reach the desired position,

we can calculate the required pulses needed by the motor to complete the rotation.

pulses
For one pulse we get 1.8o rotation and for 239 degree we will require a 133 second.

ifwe consider a 0.1ms for rising time and the same for the falling time so the total pulses for

the motor for one move will be as Total pulses = 133 + (2 ∗ 13.3) = 159.6

a
= 160 pulses for one move

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239
To complete one revolution the motor required 360
=

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0.66 present the relative value ro the action move to the full rotaion. so 242 pulses is required

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To complete one rotation.

3.3.3.2 DC motor
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For the conveyor system that do the task of transferring the clothes to the delivery area we
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can use the normal DC motor, with the precise specifications of (Torque, Revelations). How

to select the proper motor depending on the torque and rotation speed will be explained next?
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3.3.3.2.1 Calculating the DC motor torque.

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The torque of the motors is divided into running torque and the acceleration torque. Here
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because of the small size of the motor moment of inertia that will reduce the acceleration
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torque to be approximately neglected comparing to the running torque that is created by

analyzing the system kinetics (recall equations (3.1,3.2,3.3)). we will only consider the

running toque in our calculation to select the proper motor size. Because the accelerating

torque will be too small and nearly zero.

𝑇𝑇 = 𝑇𝑇𝑎𝑎𝑎𝑎𝑎𝑎 + 𝑇𝑇 𝑟𝑟𝑟𝑟𝑟𝑟

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𝑇𝑇𝑎𝑎𝑎𝑎𝑎𝑎 = 𝐽𝐽 ∗ 𝛼𝛼

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𝑇𝑇𝑟𝑟𝑟𝑟𝑟𝑟 = 𝐷𝐷(𝐹𝐹 + µ𝑚𝑚𝑚𝑚)
2

𝑇𝑇𝑎𝑎𝑎𝑎𝑎𝑎 = 𝐽𝐽𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 ∗ 𝛼𝛼

𝐽𝐽𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 = 1.2 ∗ 10−9 𝐾𝐾𝐾𝐾. 𝑀𝑀2

α=𝜋𝜋�2 𝑟𝑟𝑟𝑟𝑟𝑟�𝑠𝑠 2

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𝑇𝑇𝑎𝑎𝑎𝑎𝑎𝑎 = 1.2 ∗ 10−9 ∗ 𝜋𝜋�2

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𝑇𝑇𝑎𝑎𝑎𝑎𝑎𝑎 = 1.2 ∗ 10−9 ∗ 𝜋𝜋�2

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𝑇𝑇𝑎𝑎𝑎𝑎𝑎𝑎 = 1.9 ∗ 10−9 𝑁𝑁. 𝑀𝑀 𝑤𝑤ℎ𝑖𝑖𝑖𝑖ℎ 𝑖𝑖𝑖𝑖 𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛 𝑧𝑧𝑧𝑧𝑧𝑧𝑧𝑧 .
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For the running Torque we can use the following formula for a moving load on a conveyor

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𝑇𝑇𝑟𝑟𝑟𝑟𝑟𝑟 = 2 𝐷𝐷(𝐹𝐹 + µ𝑚𝑚𝑚𝑚) … … … … … … … … … … … … … … … … … … … … … … . . … . (3.5)
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Where T,D,m,g,µ,F are Torque(N.M),Roller diameter(M),Mass of Load(KG),Gravity

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acceleration(𝑚𝑚�𝑠𝑠 2 ) ,Friction coefficient, External force (N) respectively .

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From the design the inputs data are:

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D = 2 mm , F = 0 N, m = 0.8 KG, g=9.81 𝑚𝑚�𝑠𝑠 2 , µ = 0.3 assumed as the belt made of rubber.
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𝑇𝑇𝑟𝑟𝑟𝑟𝑟𝑟 = 𝐷𝐷(𝐹𝐹 + µ𝑚𝑚𝑚𝑚)
2

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𝑇𝑇𝑟𝑟𝑟𝑟𝑟𝑟 = ∗ 2 ∗ 10−3 (0 + 0.3 ∗ 0.8 ∗ 9.81)
2

𝑇𝑇𝑟𝑟𝑟𝑟𝑟𝑟 = 2.354 ∗ 10−3 𝑁𝑁. 𝑀𝑀

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Figure 3. 17 Kinetics analysis for the DC motor

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3.3.3.2.2 Calcualating the motor speed (revelution per minute)

The need of transfering the cloth for 400 mm lead us to search for a way of doing it. By using
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a simple DC motor we can fulfil the task. To identify the motor speed we will calcualate it
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as the total travelling distance for the cloth is 400 mm withen 1 seconed , so the speed will

equal to 400 𝑚𝑚𝑚𝑚⁄𝑠𝑠 converting this value to RPM, it will equal to 24000 𝑚𝑚𝑚𝑚�𝑚𝑚𝑚𝑚𝑚𝑚. . to make
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it revolution per minute we require to transfer the linear distance to rotational move for the
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driven/drive gear. Knowing that the raduis of the gears are 4.5 mm we can just devide the

24000 by the raduis to get the rotation angle, then devide the value by 2π we will get the
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speed for the motor per minute.

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By equations

mm 60s mm
400 s
*min. = 24000 min.

mm
rotation angle ∗ raduis = total travelling distance = 24000
min.

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 total travelling distance 24000 mm
rotation angle = raduis
= 4.5 mm
= 5334 rad .

total degrees 5334 mm

Motor revolution = 2π
= 2π
= 850 rev/min.

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400 mm

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3.3.4 Machine Control Design

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Explaining the control side of the designed machine will take place in the following sections.
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These sections will include the sequence diagram, Boolean equations, ladder logic, and

circuit diagram.
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3.3.4.1 Boolean equations

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the Boolean equations represent the relations between the output variable (Virtual and

Actual) and the programmable instructions logic. Every variable has to has a set value and
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reset value, so it can be correctly programmed and inserted to PLC. Table 3.4 shows the
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Boolean equations for our project.

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Table 3. 4 Boolean equation for the Machine logic

RUNG # Variable SET RESET

0 HRT00M1F PB+S1 TIM 01

1 TIM 00 HRT00M1F

2 M1F HRT00M1F TIM 00

3 HRT01M1BW TIM 00 TIM 01

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4 TIM 01 HRT01M1BW

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5 M1BW HRT01M1BW TIM 01

6 HRT02M2F TIM 01 TIM 03

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7 TIM 02 HRT02M2F

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8 M2F HRT02M2F TIM 02

9 HRT03M2BW TIM 02 TIM 03

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10 TIM 03 HRT03M2BW

11 M2BW HRT03M2BW TIM 03

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12 HRT04M3F TIM 03 TIM 05

13 TIM 04 HRT04M3F
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14 M3F HRT04M3F TIM 04

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15 HRT05M3BW TIM 04 TIM 05

16 TIM 05 HRT05M3BW
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17 M3BW HRT05M3BW TIM 05

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18 HRT06DCM1 TIM 05 TIM 06

19 TIM 06 HRT06DCM1

20 M1DC Running HRT06DCM1 TIM 06

21 HRT07DCM2 TIM 06 TIM 07

22 TIM 07 HRT07DCM2

23 M2DC Running HRT07DCM2 TIM 07

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3.3.4.2 Sequence diagram

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 Figure 3. 18 Sequence diagram for the machine logic

The sequence diagram describes the sequence of the desired logic intended to be done by the

engineer or the designer. Figure3.18 Shows the sequence diagram for the clothes folding

machine.

3.3.4.3 Ladder Logic

Ladder logic it is the way which the engineer transfers the data and the logic to the PLC.

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Ladder logics always done by a proper software that can be interface with the PLC without

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any problems and interruptions because it is the final step of programming to be done before

transfer the data to the PLC. Figure 3.19 Shows the ladder logic diagram for the Clothes

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Folding Machine.

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Figure 3. 19 ladder logic diagram for the machine logic

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Figure 3.19 Ladder logic diagram for the machine logic (continued)

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3.3.5 Stepper motor driver

After the selection of the stepper motor of a 1.8𝑜𝑜 step, torque (4.8 N.M ) , and 160 pulses. We

can go and select the proper stepper motor driver to do the task for providing the accurate

pulses to the motor to rotate. Because our torque and rotations are not that big values we are

not going to face any serious issue to pick a random driver with two direction rotations that

complies with the PLC and stepper motor current and voltage. Figure 3.20 present three

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different types of stepper motor drivers that do the same task of driving the motor but from

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different manufactures (STP-DRV-DL050, M542, AND TB6600). Figure 3.21 shows an

implementation of wiring connection to drive the stepper motor, we can easily see that the

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input for the drivers are the Vcc and the signals from the PLC which are the (-Pulse) and the

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(-DIR). Here we explain the driver model (STP-DRV-DLO5) from sure step automation

company. This driver is compatible to be used by PLC signal or even by microchips pulses.
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Figure 3.22 represent the wiring diagram for the driver with the PLC and Motor to introduce
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a proper understanding of our system. After complete the full Vdcc connection to the motor

and the PLC, you can find the signal output Y0 (-step), Y1(-dir) from the PLC going to the
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drivers these two signals control the motor rotation CW, CCW. As per the PLC program.
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Table 3.5 introduce the functions of activating Y0, Y1.

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Figure 3. 20 Stepper motor drivers a) STP-DRV-DLO5. b) M542. c) TB6600.

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Figure 3. 21 Implementation of drivers wiring

Table 3. 5 Connection configuration for the Stepper motor driver

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Table 3. 6 Stepper motor driver electrical specification

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Table 3. 7 Stepper motor driver signals activation table

Stages Step-/Pul- Dir- ENA - Motor Action

1 0 0 0 Driver is off/ motor off

2 1 0 0 Rotate CW

3 1 1 0 Rotate CCW

4 1 1 1 Stop running

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Figure 3. 212 Typical connection for the driver STP-DRV-DLO5 with the PLC
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 CHAPTER 4
RESULTS AND DISCUSSION

In this chapter we overview all the results and output data we found in the methodology of

chapter 3. These results will be divided in three manners. The machine hardware design and

assembly, the ladder logic outputs, and the actual simulation for the PLC.

4.1 Machine Hardware

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The figures below will show us the full assembly of the clothes folding machine with the

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exploded view. In addition of its steps after each signal from the PLC.

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4.1.1 Machine full assembly

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Figure 4. 1 Top and Front View for the machine with some dimensions

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Figure 4.1 shows the top and front view of the final machine design including the main out

dimensions, height (600 mm), width (800mm), and the depth (900mm). while the figure 4.2

shows the right view in addition with the isometric one. Note here that the right view is done

to show the hidden lines and make them visible view so we can see the internal integrated

parts of the machine.

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Figure 4. 2 Isometric view with the right view shows hidden line.

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4.1.2 Exploded View

Figure 4.3 displays the exploded view for the clothes folding machine, with annotations that

described in table 4.1.

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Figure 4. 3 Exploded view for clothes folding machine with annotations.

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Table 4. 1 Folding machine parts with ref. annotation number to the exploded view in figure 4.3
ITEM NO. PART NUMBER DESCRIPTION QTY .
1 Folding Board Oak Wooden Board 2
2 Hinge A Aluminum Hinged 3
3 Hinge B Aluminum Hinged 3
4 Central Pin Axial Pin Fixing the Hinges Parts 3
5 Pushing Arm 3
6 Pushing Hinge 3
Metric - Spur gear
7 2.5M 88T 20PA 12FW Driv en Gear / Brass 3
---S88N75H50L14S1
Metric - Spur gear
8 2.5M 30T 20PA 12FW Driv e gear 1
---S30N75H50L10S1

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9 Base St epper Mot or Assembly 3
10 Back Plat e 3

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11 Body 3
12 Axial Rod 3
AFBMA 12.1.4.1 -

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13 0050-11 - 6
10,DE,AC,10_68
B18.6.7M - M3 x 0.5 x

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14 5 Type I Cross 12
Recessed PHMS --5S
Stepper Motor
15 Mount NEMA_17 4
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Sized
16 1 belt drive hanger 7
17 Machine frame 1
Clothes
18 1
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Representation
19 Driven Gear Support 2
AFBMA 20.1 - 10-5 -
20 3
8,SI,NC,8_68
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21 Main Board Support 1

Metric - Spur gear
22 0.5M 16T 20PA 4FW - 1
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--S16N75H50L2N
23 Mot or 2
24 Dc mot or billow 1
25 1 belt Driv e 4
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26 Belt1-3^1 belt driv e 2

27 rack 1
28 conv eyor support 2
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29 board 400 x 250 (mm) Wooden board 2

Metric - Spur gear
30 2.5M 30T 20PA 12FW Driv e Gear /Brass 2
---S30N75H50L14S1
Metric - Spur gear
31 0.5M 16T 20PA 2FW - 2
--S16N75H50L1N
Metric - Spur gear
32 0.5M 16T 20PA 2FW - 1
--S16N75H50L2N
AFBMA 20.1 - 17-2 -
33 2
12,SI,NC,12_68

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4.1.3 Machine steps

After loading the proper ladder diagram to the PLC the simulated steps will be as the shown

in figure 4.4. we can easlily see when the motors are in action for the foldig steps. Figure

4.4a is explains the first step of moving the left board for its final position. Figure 4.4b also

shows the right board in action. Figure 4.4c is the middle board in action. In addition to the

siometric views for every step.

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a) b) c)

Figure 4. 4 Folding machine in action (a) left board in action. (b) right board in action. (c) middle
board in action.

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4.2 Ladder Diagram

The ladder logic program was developed and tested using the CX-Program,then loaded to the

PLC. In the following series of figures, we will comment the figures and explain them briefly

for every activated rung in the ladder diagram, showing the inputs, the outputs and their

addresses .

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Figure 4.5 shows the system condition before simulation started. then Figure 4.6 (a) and (b)

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presents the first step of the program, we can see that the open contactor dresses by 0.00

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stands for the Push Button which is connected in series with the input switch 0.01 which

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stands for the board sensor that defines if the cloth exists on the board or not. Then timer

T0001 is the one for reseting the output for the rung which is the vertual Holding relay
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adressed 100.10 to run the first motor forward by activating the T0000. We can see also that

all the contactors are all high in the first rung in figure 4.5a, while the sensor is already off
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in figure 4.5b. even though the output still high because of the latch connection 100.10. we
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can also see that the 2nd rung is taking the responsibilty to activate the physical output (

represented by a led in the PLC) addressed by 100.00. which stands that the siganl is sending
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to the motor driver while the timer T0000 is on. Keep in mind that these steps are typically
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done for all the motors in the machine to be forward drive.

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Figure 4. 5 Condition of OMRON PLC before simulation started

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 a)

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Figure 4. 6 Ladder logic diagram activation (a) physical inputs responsible for high output (b) latch
100.10 is keeping the output high.
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figure 4.7 shows how the backward rotation for the motors are controlled. In rung 3 in the
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ladder diagram the timer T000 is latched by the output 100.11 which present the vertual

holding relay for the backward Timer on rotation. The timer T0001 is set on by 100.11 and
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reseted by the same holding relay after T0001 time is finish. Rung 5 explains the physical
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output for the ladder logic in the PLC addressed by 100.01 which is shown as a led. You have
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to note that both outputs are high for rotating the motor in the back ward side as per the driver

STP-DL05 specs requires (Y0,Y1).

53
 Figure 4. 7 The logic sequence of backward rotation for motor 1

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Figure 4.8 shows the forward sequence for the second motor. Virtual relay setted by the timer

T001 and reseted by the Timer T0002 that activate the forward motor by keeping the relay

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100.12 on.

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Figure 4. 8 The logic sequence of forward rotation for motor 2

Figure 4.9 shows the backward sequence for the second motor. Virtual relay 100.13 setted
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by the timer T0002 and reseted by the Timer T0003 that activate the forward motor by
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keeping the relay 100.13 on.

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Figure 4. 9 The logic sequence of backward rotation for motor 2

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Figure 4. 10 Ladder diagram while activating the conveyor DC motors

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Figure 4.10 shows the DC motors activated in the rung 20 and 23 under the addresses of

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Q100.06, Q100.07.

4.3 Simulation Using OMRON PLC Training Kit

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Having an over view of the system simulation by the PLC we be discussed in this sub-chapter.
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Figure 4.11 represent the condition of the OMRON PLC before the program been in action.

We can clearly see the inputs switches ( PB,S1,S2) and the outputs
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(Y0,Y1,Y2,Y3,Y4,Y5,Y6,Y7).
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S0 S1 S2

Figure 4. 11 Omron PLC on standby condition

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Once we activate the system by the Push Button (S0) and with the cloth reading sensor (S1)

that fixed on the main wood boards, the system starts to run. The first step of the system is

implemented by the figure 4.12 where we can see that the output Y0 is high and the led

number 0 is on. This activation means that the first stepper motor is running forward by

receiving this signal.

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Figure 4. 12 The first motor receives the signal and running
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Changing the status of the switches (S0, S1) from active to Off will not stop the system,

since, the system is already latched by the virtual holding relay 100.10. this can be seen by
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figure 4.13.
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Figure 4. 13 Holding relay latch keeps the system ON

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In Figure 4.14 we can see that the both outputs Y0, Y1 are high and the led numbers (0,1)

are on, indicating that the stepper motor is running backward as per the motor driver

specifications that when the both (Pulse-/step-) and the Dir- are high the motor will change

his way of rotation.

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Figure 4. 14 The first motor receives the signal and running
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Figure 4.15 shows the motor 2 in action for the second folding step by the second wooden

board. The output Y2 are high and the led 2 are on. Indicating that the second motor is running
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forward.
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Figure 4. 15 The second motor receives the signal and running forward

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Figure 4.16 represent the backward movement for the second motor when the both outputs

are high Y2, Y3 and the leds 2,3 are on. Here the driver of the stepper motor receives the

signal from the PLC to reverse the forward rotation and make it backward.

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Figure 4. 16 The second motor receives the signal and running backward
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The third action of the machine is impelemented by figure 4.17 for the third stepper motor,

the led 4 are on means that the output Y4 is high, and the driver is receiving the signal to run
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the motor forward.

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Figure 4. 17 The third motor receives the signal and running forward

Moving the third wooden board back to its desired postion is done impemented by the figure

4.18 where we can see the leds 4,5 are on and the outputs Y4,Y5 are high to ignite the motor
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driver to run back the motor. If you follow the ladder diagram rung number 19 you will see

that this leds will be on more time than the others. Because the board has to move backward

more than the forward angle position.

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Figure 4. 18 The third motor receives the signal and running backward
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Running the DC motors with the PLC signal is presented in the figure 4.19 where we can see

that led 6,7 are on and the outputs Y6, Y7 are high. These motors are responsible to deliver
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the cloth to its desired final position to be delivered to the operator.

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Figure 4. 19 Indicators are on as DC motors are in action

in figure 4.20 we can see that if we activate the stop button switch S2, the program will be

inturrupted and the machine will stop running since all the input signals has been stopped.
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Figure 4. 20 Switch 2 activated to stop the system from running

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Once the PLC activated and the DC motors are running we can note that the second DC

motors still running (led 7 is on) while the first one is off ( led 6) in figure 4.21 and this is

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represets the ladder logic timer time, since we keep it on for more seconds than the first

motor.

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Figure 4. 21 Second DC motor still on while the first one is off.

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figure 4.22 shows the final shape of the cloth after finishing the task. In this shape the clothes

will be delivered to the operator by the machine.

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 Figure 4. 22 Final shape of folded cloth, delivered by the machine.

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 CHAPTER 5
DISCUSSION AND RECOMMENDATION

Our goal in this research was trying to introduce a fully automation system, that identifies

how the integrity of a pure mechanical with a control system can be smoothly go to achieve

the desired aims.

5.1 Conclusion

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Designing the clothes folding machine was an improvement of the manual steps where

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normal humans used to fold their clothes, and make it fully automatic. Fully automatic mean

you just drop your piece of cloth inside the machine and it will deliver it to you folded within

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a short time. But facing obstacles as the difference in clothes shapes and categories forced us

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to choose just one type of these clothes and simulate our machine to fold it. This shape was
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the T-shirts, where we try folding it within six series steps. Shown in figure 5.1
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Figure5. 1 Final shape of folded cloth, delivered by the machine.

After reaching to the suitable design through many drafts and sketches, engineers software

takes a place to develop the machine assembly and control. Using solidworks was a wise

decision to complete the task of drawings, and parts assembly even to animate the machine.

Then heading to CX-Program that can interface easily with the PLC OMRON which we use

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to simulate the machine movements by. It was essential for the designer to build the ladder

logic diagram for testing the system and simulate it with the CX-program before transferring

it to the PLC where he can put his design in action.

Using the human intelligence in the process was one of weak point of this machine. Operator

still has to feed the cloth with a proper way, so the machine can fold it easily. From here we

can see that the machine was designed to do only a few certain simple steps to fold the cloth,

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not to make it complex and more intelligent.

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5.2 Recommendations

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For future work, and after building the first prototype of the machine and test it, it is necessary

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to integrate this machine with others, to make it more easy for the operator to deal with it.
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These integrated machine could be like design a way to feed the machine with clothes as

hanging the clothes form the shoulders and feed them to the core of the machine, or even
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improve it more like adding a box where the machine can decide the shape of the clothed by

itself using advance image processing and artificial intelligence science. This step surely need
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a high precise cameras and huge data collection to do the image processing for the feed cloth.
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5.3 What we gain by going through this machine design?

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Programming the control is surely depending on the controller type itself. Here we use the
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PLC to simulate the task, if PLC is not available or expensive. Still you can find your

controller by using the Arduino kit, where it can easily interface with the stepper and DC

motors in the machine using a proper driver. All of these electronic devices has to be

technically applicable for interfacing each other. Specifically, the current value that present

the key of running the electronic devices.

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REFERENCES

Bersch, C., Pitzer, B., & Kammel, S. (2011). Bimanual Robotic Cloth Manipulation for Laundry
Folding. Paper presented at the International Conference on Intelligent Robots and
Systems, San Francisco, CA, USA.
Doumanoglou, A., Stria, J., Peleka, G., Mariolis, I., Petrık, V., Kargakos, A., . . . Malassiotis, S. (2016).
Folding Clothes Autonomously- A Complete Pipeline. IEEE Transactions On Robotics.
Estevez, D., Victores, J. G., Morante, S., & Balaguer, C. (2016). Towards Robotic Garment Folding.
Paper presented at the International Conference on Autonomous Robot Systems and

a
Competitions. https://ieeexplore.ieee.org/document/7781974/
Hamada, T., Hata, S., Hojoh, H., Kobayashi, H., & Fukumoto, Y. (2009). Flexible Handling Robot

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System for Cloth using 3-D Sensor. Paper presented at the IEEE Workshop on Advanced
Robotics and its Social Inpacts, Tokyo, Japan.
Hata, S., Hojoh, H., Toda, M., & Hamada, T. (2011, August 7-10). Cloth Handling System for Linen

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Supply Industry. Paper presented at the International Conference on Mechatronics and
Automation, Beijing, China.

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Hubli, P. V., Alekhya, S., Vijayakumar, S., Prasad, T., Hegde, V. N., & Rao, K. N. (2017).
Mechanization of Cloth Plication.
Mahajan, M. P., Prasad, S., Binnar, T., & Tambe, M. (2017). Automatic T-shirt Folding Machine.
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Maitin-Shepard, J., Cusumano-Towner, M., Lei, J., & Abbeel, P. (2010). Cloth Grasp Point Detection
based on Multiple-View Geometric Cues. Paper presented at the IEEE International
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Miller, S., Berg, J. v. d., Fritz, M., Darrell, T., Goldberg, K., & Abbeel, P. (2015). A geometric
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