Thread Vision

The challenge

Every broken end on a ring frame is a spindle producing nothing while material goes to waste. Our client relied on patrollers walking the frames to find breaks: labor-intensive, with each break waiting for the next patrol round, and no view of patterns such as which spindles and frames break most.

What we built

An autonomous vision platform runs continuously back and forth on a rail in front of the frame. Its camera scans the spindles and our custom machine-vision pipeline spots broken ends. Collision sensors reverse it around workers and obstructions; if both ways are blocked, it waits and restarts on its own. Onboard sensors log temperature and humidity as it travels.

When a break is found

• On the frame: the status light turns yellow and the screen shows the status of every spindle.
• On the floor: patrollers get a notification with the exact frame and spindle.
• In the office: the plant manager sees every frame live on a digital-twin dashboard laid out like the factory floor.

Every event logged

Each break and fix is recorded for audit and reporting: time to fix, breakages by spindle and frame, breakage against temperature and humidity, and breaks and fixes per hour, shift, day and month.