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BobbinSense: Automatic Bobbin Diameter Monitoring

A purpose-built measurement and alert system designed to help operators monitor bobbin diameter and know when a bobbin needs attention.

FIBCSensor measurementEmbedded controlOperator alert
THE CHALLENGE

Measure the process without over-engineering the machine

Bobbin diameter is a production parameter that operators need to monitor consistently. A conventional PLC-based measurement rig can be effective, but the cost becomes significant when several production lines need the same capability.

Brinito approached the requirement as a focused measurement product: select the right sensor, build the embedded control logic, provide an operator interface and make the system practical for repeated deployment.

PROJECT SNAPSHOT
ApplicationBobbin diameter monitoring
IndustryFIBC / woven manufacturing
ArchitectureSensor + embedded controller + operator interface
BenchmarkProject documentation reports approximately 50% lower hardware cost than a PLC-only rig
SYSTEM ARCHITECTURE

Measurement → decision → operator action

The design focuses on the information the operator actually needs while keeping the electronics and control architecture appropriate to the application.

BobbinPhysical process
SensorDiameter signal
ControllerMeasurement logic
ThresholdDecision point
AlertOperator action
ENGINEERING WORK

What Brinito handled

  • Sensor selection and measurement architecture
  • Embedded controller and measurement logic
  • Operator display / alert behaviour
  • Calibration and application-specific thresholds
  • Industrial installation and commissioning approach
WHY IT MATTERS

A repeatable automation building block

The value is not only the individual measurement. A compact, purpose-built system can be replicated across lines where the same production condition needs to be monitored.

MeasurementEmbeddedAutomationFIBC
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FREE DOWNLOAD // PLANT-FLOOR READINESS

The Plant Manager's Industry 4.0 Readiness Checklist

A short, practical PDF covering how to audit legacy PLC lines, calculate ROI on sensor retrofits, and brief an integrator like Brinito Services PVT LTD in one meeting instead of five.