Warponic

Abstract

The textile industry relies heavily on warp preparation, an essential process in weaving. Traditional warp preparation in handloom sectors is performed manually, requiring skilled labor and significant time. Manual operation often leads to inconsistenttension,misalignment, and errors thatreduce fabricquality.Thisprojectaims to design and implementa fullyautomatic warp preparation system that eliminates human intervention, maintains consistent yarn tension, and improves operational efficiency. The proposed system employs an ESP32 microcontroller for control and automation, stepper motors for precise motion, a load cell for tension sensing, and PID control logic for maintaining uniform yarn tension. The system is capable of automatically windingthe warp yarn onto the beam with high accuracy in terms of length and tension. A graphical interface allows users to set desired warp parameters such as tension, length, and speed. The developed prototype reduces preparation time by over 60%, improves uniformity, and enhances repeatability. This system demonstrates the feasibility of low-cost automation in small and medium hand

Introduction

This project focuses on developing a low-cost, compact, and fully automatic warp preparation system for small-scale and handloom weavers. Traditional manual warping is time-consuming, labor-intensive, and prone to tension inconsistencies that affect fabric quality. Existing industrial automatic warping machines are expensive and unsuitable for rural or small-scale use.

The proposed system automates beam winding and yarn tension control using a closed-loop PID feedback mechanism, eliminating manual intervention and ensuring uniform yarn tension. An ESP32 microcontroller controls stepper motors, sensors, and a user interface. Key components include a load cell with HX711 amplifier for tension measurement, a rotary encoder for length and speed tracking, motor drivers, and a TFT display for easy parameter setting.

The system was designed through structured phases: requirement analysis, mechanical and electrical design, software development, integration, and testing. Experimental results showed consistent tension, reduced warping time, improved fabric uniformity, lower labor dependency, and energy-efficient operation. The system also supports digital and IoT integration for monitoring and data logging.

A literature review revealed a research gap in low-cost, fully automated warp preparation solutions for small-scale weaving, which this project successfully addresses.

Future enhancements include automatic fabric take-up, advanced tension control, smart monitoring via mobile apps, industrial-scale upgrades, and solar-powered operation, making the system scalable, sustainable, and suitable for rural applications.

Conclusion

The project successfully demonstrated an automatic, low-cost weaving system capable of operating without manual involvement. By integrating Arduino control, servo motors, and stepper-driven shuttle movement, the prototype efficientlyautomated the mainfunctions of a traditional loom. Itachievedconsistentperformance withgoodfabricqualityandsignificantlyreducedhumaneffort,time,anderrorcomparedtomanual weaving. The prototype is economical, energy-efficient, and easily upgradable, making it suitable for educational projects, small textile units, and rural entrepreneurs. In conclusion, this project proves that automation in traditional handlooms is feasible and affordable. With further optimization and mechanical improvements, this system can evolve into a fully automatic, smart weaving machine that supports small-scale industries sector.

References

[1] S.R.KhurmiandJ.K.Gupta,ATextbookofMachineDesign,EurasiaPublishingHouse,2015. [2] M.K.Gandhi&B.S.Sharma,TextileDesignandWeavingTechnology,CBSPublishers&Distributors,2018. [3] J.E.Booth,PrinciplesofTextileTesting,Newnes-Butterworths,1996. Research Article: [4] Patil,R.&Deshmukh,S.(2021).?AutomationofHandloomUsingArduino.?InternationalJournalofInnovativeResearchin Electrical, Electronics, Instrumentation and Control Engineering (IJIREEICE), Vol. 9, Issue 4. [5] A. K. Sharma, ?Low-Cost Automation in Textile Weaving Industry,? International Journal of Engineering Research and Technology (IJERT), Vol. 10, No. 5, 2021. YouTubeTutorialsandMakerCommunityResources: [6] AutomaticLoomMechanismusingArduino?–YouTube, 2023 [7] ServoMotorControlwithArduino?–ArduinoProjectHub IEEEPaper: [8] M. Patel et al., ?Design and Fabrication of Automated Weaving Machine,? IEEE Xplore, 2020

Copyright

Copyright © 2026 Mrs. R. S. Ghat, Ms. Pranali Shankar Gurav, Ms. Manasi Sarang Powar, Ms. Purva Prakash Patil, Ms. Atharv Madhukar Powar. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.