Textile Research Journal

http://trj.sagepub.com A Neural Network System for Prediction of Thermal Resistance of Textile Fabrics
Debarati Bhattacharjee and ViJay K. Kothari Textile Research Journal 2007; 77; 4 DOI: 10.1177/0040517506070065 The online version of this article can be found at: http://trj.sagepub.com/cgi/content/abstract/77/1/4

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Textile Research Journal

Article

A Neural Network System for Prediction of Thermal Resistance of Textile Fabrics

The objective of this paper is to report a study on the predictability of the steady-state and transient thermal properties of fabrics using a feed-forward, back-propagation artificial neural network system. A comparison was made with two different network architectures, one with two sequential networks working in tandem fed with a common input and another with a single network that gave two outputs. A three-layered network was used in both the cases. The networks were then subjected to a set of untrained inputs and the output thermal properties, namely thermal resistance and Qmax, were compared with the values obtained experimentally. The architecture with two networks working in tandem with a common set of inputs gave better results than the architecture with one set of inputs used to give two outputs.

Abstract

Debarati Bhattacharjee and Vijay K. Kothari1

Department of Textile Technology, Indian Institute of Technology, Hauz Khas, New Delhi-110016, India

Key words clothing comfort, woven fabrics, instantaneous heat transfer, neural network, thermal resistance
Comfort is one of the most important attributes of textiles used in clothing. Clothing comfort is influenced by (i) fabric factors viz. fiber conductivity, fabric parameters, air contained within the fabric etc; (ii) environment factors viz. temperature, humidity and wind speed; and (iii) human factors viz. color, fashion, psychology of the wearer, etc. Thermal properties of clothing are one of the most important aspects of clothing comfort. Many studies have been conducted to analyze the relationship between various fabric parameters and comfort properties by using statistical methods [14]. However, the statistical methods used have some limitations. One of the most common problems faced in statistical modeling is the non-linear relationship of different fabric parameters with thermal comfort properties. Furthermore, most of the fabric parameters which directly influence the thermal properties such as thickness, fabric weight, porosity, etc. are related to each other and are derived from basic fabric specifications such as yarn linear density, thread spacing, etc and hence it is difficult to study the effect of one parameter without changing the other. Therefore a system is required which can predict the thermal parameters of the fabric by considering the collective influence of all the fabric parameters at the same time. This is where artificial neural network can be effectively put to use. Artificial neural network (ANN) has proved useful for many prediction-related problems in textiles such as the prediction of characteristics of textiles; identification, classification and analysis of defects; process optimization; and marketing and planning [57, 11, 15]. Researchers have already tried to use neural networks to predict various comfort-related properties such as human sensory perceptions and overall comfort index [810, 12, 16].1 In this paper artificial neural network is used to predict the steady-state thermal resistance and maximum instantaneous heat transfer Qmax of a fabric when the fabric weaving and construction parameters are given as inputs. Two different network architectures were studied. In one case, the

1 Corresponding author: tel: +91 11 26591401; fax: +91 11 26581103; e-mail: kotharivk@gmail.com

Textile Research Journal Vol 77(1): 412 DOI: 10.1177/0040517506070065

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A Neural Network System for Prediction of Thermal Resistance D. Bhattacharjee and V. K. Kothari whole ANN system consisted of two neural networks working in tandem with a common input and in another case, the ANN system consisted of one network with two outputs. These two systems were then compared for their prediction performance. The networks were trained with a training data set and then tested with a set of untrained values of fabric parameters. The steady-state thermal resistance and instantaneous heat flow Qmax values obtained from the network were compared with actual values obtained from the instrument. Table 1 Training set fabric specifications.
S. no. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. Weave 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 2/2 twill (2) 2/2 twill (2) 2/2 twill (2) 2/2 twill (2) 2/2 twill (2) 4 end satin (3) 4 end satin (3) 4 end satin (3) 4 end satin (3) 4 end satin (3) 4 end satin (3) 4 end satin (3) 4 end satin (3) Plain (4) Plain (4) Plain (4) Warp count Weft count (Ne) (Ne) 2/40 2/40 2/40 2/40 2/40 2/40 41 39 37 42 2/34 2/36 2/38 39 20 20 3/60 20 16 2/40 2/40 38 2/38 2/50 2/40 16 2/40 2/38 2/39 2/40 2/38 2/40 2/40 2/40 2/40 2/40 2/50 2/41 2/40 39 39 36 2/40 2/40 2/40 16 2/38 2/38 36 2/36 2/36 2/70 17 2/26 29 2/28 16 10 3/30 20 12 2/40 2/38 27 2/54 2/50 2/20 10 19 2/36 2/38 2/38 2/40 20 2/40 2/40 2/40 2/36 2/50 2/40 2/20 39 38 2/70 EPI 116 118 120 122 126 124 148 140 150 148 126 126 126 142 124 120 128 110 128 118 128 148 128 150 120 104 128 124 124 120 124 122 122 124 120 122 150 122 126 142 140 144 PPI 58 54 56 58 60 58 104 86 84 104 80 68 92 76 64 58 58 58 54 60 56 96 92 70 58 54 60 60 62 56 52 56 62 50 56 56 78 60 72 56 94 92 Thickness (mm) 0.50 0.49 0.52 0.49 0.47 0.49 0.44 0.39 0.38 0.29 0.42 0.50 0.38 0.42 0.35 0.40 0.36 0.41 0.51 0.49 0.47 0.32 0.38 0.37 0.37 0.55 0.48 0.45 0.50 0.46 0.53 0.50 0.47 0.42 0.45 0.43 0.38 0.47 0.49 0.37 0.23 0.22 Weight (GSM) 222 210 215 226 226 217 151 191 196 155 242 265 218 216 236 300 245 210 315 221 213 169 228 220 295 285 226 218 226 215 214 227 217 209 215 223 220 219 335 173 144 145 Thermal resistance (K.m2/W) 0.0086 0.0085 0.0095 0.0087 0.0080 0.0090 0.0097 0.0074 0.0071 0.0058 0.0069 0.0091 0.0073 0.0084 0.0051 0.0051 0.0040 0.0061 0.0064 0.0089 0.0081 0.0061 0.0070 0.0054 0.0046 0.0082 0.0086 0.0077 0.0088 0.0079 0.0099 0.0091 0.0085 0.0070 0.0078 0.0073 0.0054 0.0085 0.0065 0.0075 0.0049 0.0047 Qmax

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Materials and Methods

A total of 86 samples of cotton woven fabric samples were taken for the study, of which 70 samples (approx. 81%) were used for training and 16 for testing of the network. The specifications of these fabrics are given in Tables 1 and 2. There were a total of six different weave sets which were given a numeric value of 1 to 6 (given in parentheses). The thermal properties of these fabrics were measured using a

( 103 W/m2) 0.649 0.665 0.628 0.680 0.670 0.619 0.600 0.636 0.639 0.680 0.740 0.632 0.655 0.636 0.845 0.832 0.901 0.703 0.719 0.631 0.656 0.689 0.710 0.826 0.901 0.663 0.655 0.684 0.647 0.672 0.568 0.627 0.639 0.657 0.675 0.671 0.715 0.660 0.718 0.599 0.703 0.746

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Table 1 Training set fabric specifications. (continued)

S. no. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. Weave Plain (4) Plain (4) Plain (4) Plain (4) Plain (4) Plain (4) Plain (4) Plain (4) Plain (4) Plain (4) Plain (4) Plain (4) Plain (4) 2/1 twill (5) 2/1 twill (5) 2/1 twill (5) Complex (6) Complex (6) Complex (6) Complex (6) Complex (6) Complex (6) Complex (6) Complex (6) Complex (6) Complex (6) Complex (6) Complex (6) Warp count Weft count (Ne) (Ne) 37 37 38 2/38 2/38 2/38 2/16 60 16 2/40 2/40 20 10 12 7 7 46 49 50 2/74 42 49 39 2/90 2/64 37 13 15 19 20 36 28 2/40 20 10 54 16 2/40 2/40 20 10 20 10 15 50 2/104 45 2/73 40 50 32 2/100 2/70 32 12 16 EPI 136 140 132 120 118 114 46 110 98 112 102 100 70 82 78 74 144 130 120 122 71 114 122 160 164 94 132 115 PPI 68 66 70 56 50 50 42 82 54 64 74 66 42 46 52 54 78 88 86 80 58 88 66 82 62 66 90 72 Thickness (mm) 0.31 0.29 0.22 0.38 0.41 0.42 0.41 0.11 0.37 0.28 0.23 0.32 0.44 0.41 0.56 0.65 0.20 0.32 0.20 0.30 0.27 0.19 0.20 0.15 0.09 0.27 0.13 0.15 Weight (GSM) 161 166 127 192 197 197 235 75 240 210 215 205 275 227 428 365 116 97 92 111 124 103 129 119 139 132 110 115 Thermal resistance (K.m2/W) 0.0064 0.0059 0.0048 0.0072 0.0075 0.0077 0.0071 0.0026 0.0057 0.0039 0.0033 0.0050 0.0058 0.0071 0.0085 0.0116 0.0037 0.0041 0.0038 0.0054 0.0063 0.0046 0.0040 0.0032 0.0016 0.0055 0.0019 0.0023 Qmax ( 103 W/m2) 0.684 0.686 0.688 0.644 0.663 0.635 0.623 0.417 0.751 0.853 0.868 0.776 0.732 0.613 0.622 0.551 0.823 0.875 0.842 0.801 0.663 0.635 0.535 0.581 0.766 0.507 0.639 0.830

Table 2 Test set fabric specifications.

S. no. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Weave 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 3/1 twill (1) 2/2 twill (2) 2/2 twill (2) 4 end satin (3) 4 end satin (3) 4 end satin (3) Plain (4) Plain (4) Plain (4) 2/1 twill (5) Complex (6) Complex (6) Complex (6) Warp Weft count count (Ne) (Ne) 2/34 6 2/40 10 2/38 2/40 2/38 2/40 30 38 2/36 2/38 9 2/35 2/78 41 2/32 6 2/20 8 2/36 2/40 19 2/36 10 38 2/60 2/30 13 2/36 2/78 44 EPI 126 64 120 70 116 122 116 120 164 140 122 116 72 192 100 105 PPI 76 40 60 44 62 52 50 50 48 80 56 42 46 64 78 79 Thickness (mm) 0.45 0.96 0.33 0.56 0.46 0.49 0.50 0.49 0.34 0.28 0.37 0.32 0.50 0.29 0.29 0.26 Weight (GSM) 245 534 300 317 226 211 208 211 255 151 192 213 292 134 122 89 Thermal resistance (K.m2/W) 0.0074 0.0134 0.0050 0.0077 0.0079 0.0091 0.0091 0.0083 0.0046 0.0060 0.0071 0.0056 0.0092 0.0034 0.0055 0.0037 Qmax ( 103 W/m2) 0.672 0.638 0.758 0.856 0.665 0.622 0.642 0.670 0.841 0.675 0.673 0.600 0.624 0.866 0.724 0.641

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A Neural Network System for Prediction of Thermal Resistance D. Bhattacharjee and V. K. Kothari

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Figure 1 Line diagram of Alambeta.

thermal resistance testing instrument Alambeta. A line diagram of Alambeta is given in Figure 1. In this instrument the fabric is kept between the hot and cold plates; the hot plate comes in contact with the fabric sample at a pressure of 200 Pa. As soon as the hot plate touches the surface of the fabric, the amount of heat flow from the hot surface to the cold surface through the fabric is detected by heat flux sensors. There is also a sensor which measures the thickness of the fabric. These values are then used to calculate the thermal resistance of the fabric. This instrument also gives the transient or instantaneous thermal properties of the textile material in terms of maximum heat flow (Qmax) within 0.2 seconds of contact with the hot plate and thermal absorptivity (b). The maximum heat flow Qmax was taken as the second output for the neural network.

neurons connected with a bias, connecting links or weights, and summation and transfer function.

Back Propagation
A feed-forward network is a network which receives inputs only from previous layers: i.e., the output of one layer is the input for the next layer and there is no feedback from the output to the input, as shown in Figure 3 [13]. The error is reduced by checking the output values with the original training output. One way to reduce the error is back-propagation (or error back-propagation). One iteration example of the back-propagation is given as follows: xk + 1 = xk k gk (1)

Artificial Neural Network (ANN)

ANN can be defined as an interconnection of neurons such that the neuron outputs are connected through weights, along with biases to all other neurons [13]. A typical ANN consisting of three layers used for the present work is given in Figure 2. Information is passed from one neuron to the other through connecting links using some transfer function. Each connecting link is characterized by a weight. Generally, an external bias to each neuron is applied that increases the net input of the activation function. Thus, one layer in a multi-layer neural network typically consists of

where xk is a vector of current weights and biases; gk is the current gradient; and k is the learning rate. Here the weights and biases are adjusted according to the error between the output layer and the training outputs. A typical back-propagation algorithm is given in Figure 4 [13]. A combination of feed-forward and back-propagation makes the network more robust, less complicated and faster to train. Hence, in the present study, a back-propagation, feed-forward neural network having three layers with two hidden layers was used. Matlab neural network tool box was used for all the programming [14]. A sigmoid transfer function tansig was used for input and hidden layers and a linear function was used for the output layer. The network was scaled by normalizing the mean and standard deviation. This was done with the func-

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Figure 2 Architecture of a threelayered network used for present work.

tion prestd so that the inputs and targets have zero mean and unity standard deviation. The error between the network output and the actual output was indicated by the mean square error (mse). The mse can be calculated as
Q

farb, and Shanno (BFGS) update. Quasi-Newton algorithms are a class of algorithms that is based on Newtons method (equation (3)), but does not require calculation of second derivatives. xk + 1 = xk Ak gk
1

(3)

1mse = --Q

k=1

[t(k) a(k)]

(2)

where t is the target output; a is the predicted output from the neural network; Q is the number of input vectors.

Training Function
The training function used was trainbfg, which is a quasiNewton algorithm based on the Broyden, Fletcher, Gold-

where Ak is the Hessian matrix (second derivatives) of the performance index at the current values of the weights and biases. Although Newtons method converges faster, it is complex as Hessian matrix of the weight and bias vector is computed at each level and therefore it takes a large amount of processor memory. This disadvantage is overcome by using a quasi-Newton algorithm which converges slower but is memory efficient. In the quasi-Newton method, the Hessian matrix at each iteration of the algorithm is computed as a function of the gradient.

Regularization
There is always a problem of over-fitting of the network during training. This happens when the network, although managing to map the training set, is not able to generalize the new test data properly. There are two ways to improve the generalization viz. regularization and early stopping. In the present study regularization was carried out to avoid over-fitting [14]. This is done by modifying the performance function mse (equation (2)). The new function called msereg is given by Figure 3 Block diagram of a feed-forward network. msereg = mse + ( 1 )msw (4)

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A Neural Network System for Prediction of Thermal Resistance D. Bhattacharjee and V. K. Kothari

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Figure 4 Back-Propagation Algorithm Flowchart.

1 msw = -n

j=1

wj

(5)

Where msw is mean square weights; is the performance ratio (default value 0.5).

Case Studies
In the present study two cases of ANN were considered as described below. Case 1: The input parameters viz. type of weave, warp and weft count (resultant count in case of two-ply yarns), thread density, thickness and areal density were considered as the input parameters. The ANN system consisted of two neural networks working in tandem with one common set of inputs. Both the networks had three layers with two hidden layers. Number of input nodes in the input layer was seven (equal to number of input parameters), while the output layer neuron was one in each network. The first network had an output of thermal resistance and the second network had an output of Qmax. The number of neurons in

the hidden layers was 10 and 8 in first and second layer in the first network and 5 and 7 in the first and second layer in second network. This number was achieved by training the ANN system with different numbers of hidden layers and obtaining the best combination possible with maximum coefficient of correlation and minimum error. The architecture of the network is given in Figure 5. Case 2: In this case the ANN system consisted of one neural network with seven inputs (same as Case 1) and two outputs viz. thermal resistance and Qmax. The network architecture is given in Figure 6. The number of neurons in the hidden layers was 7 and 15, respectively.

Results and Discussion

The comparison of various performance parameters in both the cases is given in Table 3. Case 1 has a mean error percentage of 8.61% whereas Case 2 has a mean error percentage of 10.42%. The coefficients of determination between the actual and predicted values in both cases are given in Figures 7 and 8. The number of hidden layers is less in Case

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Figure 6 Network architecture of Case 2.

Figure 5 Network architecture of Case 1.

to represent the property or there could be some other parameter that affects the transient heat transfer behavior of the fabric. The performance goal (msereg) was reached by training the network with different specifications and obtaining the best possible results in terms of error percentage and coefficient of determination of the test data. Both the cases show over-fitting in some data sets but the maximum error is lesser in Case 1 than Case 2.

1 therefore the processor memory consumed for the iterations is much less as compared to Case 2. Case 1 gives a high coefficient of determination for both output parameters, although the values in the case of Qmax are less in both cases. This may be because not enough inputs were chosen

Prediction Performance
It could be seen that the network system in Case 1 was able to predict the steady-state and transient thermal behavior with a good coefficient of determination and less average

Table 3 Comparison of the two networks.

Case 1 Resistance Network architecture Goal (msereg) Epochs Average elapsed time (s) Training set Average error (%) Maximum error (%) Minimum error (%) Coefficient of determination (r2) Test set Average error (%) Maximum error (%) Minimum error (%) Coefficient of determination (r2) 8.33 27.03 0.83 0.94 8.89 37.43 0.13 0.64 9.48 27.03 0.47 0.69 11.42 39.47 0.99 0.46 5.13 3.75 0.22 0.98 1.43 5.19 0.01 0.99 5.09 31.75 0.00 0.98 2.27 8.01 0.00 0.98 71081 0.049 40 11 Qmax 7571 0.08 424 90 Resistance 7752 0.08 120 40 Case 2 Qmax

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Figure 7 Correlation between actual values and predicted values of (a) thermal resistance and (b) Qmax for test set in Case 1.

Figure 8 Correlation between actual values and predicted values of (a) thermal resistance and (b) Qmax for test set in Case 2.

error as compared with Case 2. However, the coefficient of determination of Qmax was lower than the steady-state thermal resistance, in spite of very low average error percentage. This could be because the input parameters were not enough for the network to predict the output properly. Properties such as the surface characteristics can change the transient thermal behavior of the fabric but they were not taken into account. Therefore the output values of Qmax, in spite of having a very much smaller average individual error made a marginal contribution to the overall coefficient of determination.

tion of the thermal behavior of the fabrics. The above study, therefore, shows that artificial neural networks can be used as a tool to predict the steady-state and transient thermal behavior of a fabric satisfactorily.

Literature Cited
1. 2. Chen, Y. S., Fan, J., and Zhang, W., Clothing Thermal Insulation during Sweating, Textile Res. J. 73(2), 152157, (2003). Farnworth, B., Mechanism of Heat Flow through Clothing Insulation, Textile Res. J. 53, 717725, (1983). Hoge, H. J., and Fonseca, G. F., The Thermal Conductivity of a Multilayer Sample under a Variety of Experimental Conditions, Textile Res. J. 34, 401410, (1964). Zhang, P., Gong, R. H., Yanai, Y., and Tokura, H., Effects of Clothing Material on Thermoregulatory Responses, Textile Res. J. 72(1), 8389, (2002). Chandramohan, G., and Chellamani, K. P., Application of ANN in Yarn Manufacturing, Asian Textile J. 11(11), 5862, (2002). Mukhopadhyay, A., Application of Artificial Neural Networks in Textiles, Textile Asia 33(4), 3539, (2002).

Conclusions
Two ANN systems were studied to predict the steady-state and transient thermal properties of a fabric. One had two back-propagation feed-forward networks working in tandem with a common set of inputs whereas the other had a three-layer network with two outputs. It was found that different networks for different outputs gave a better predic-

3.

4.

5. 6.

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12. Hui, C. L., Lau, T. W., Ng, S. F., and Chan, K. C. C., Neural Network Prediction of Human Psychological Perceptions of Fabric Hand, Textile Res. J. 74(5), 375383, (2004). 13. Zurada, J. M., Introduction to Artificial Neural Systems, 2nd Edition, Jaico Publishing House, Mumbai, (1997). 14. Demuth, H., and Beale, M., Neural Network Toolbox, Users Guide Version 4, The Mathworks Inc.,http://www.mathworks.com/access/helpdesk/help/pdf_doc/nnet/nnet.pdf, (October 2004). 15. Kuo, C. F. J., and Lee, C. J., A Back Propagation Network for Recognizing Fabric Defects, Textile Res. J. 73(2), 147151, (2003). 16. Mogahzy, A. Y., Gupta, B. S., Parachuru, R., Broughton, R., Abdel-Hady, F., Pascoe, D., Slaten, L., and Buschle-Diller, G., Design Oriented Fabric Comfort Model, Project No.S01AE32, National Textile Centre Annual Reports, http://www. ntcresearch.org/pdf-rpts/AnRp03/S01-AE32-A3.pdf, (November 2003).

Mukhopadhyay, S., and Siddiquee, Q., Artificial Neural Networks and their Use in Textile Technology, Asian Textile J. 12(3), 7277, (2003). 8. Park, S. W, Hwang, Y. G., and Kang, B. C., Applying Fuzzy Logic and Neural Networks to Total Hand Evaluation of Knitted Fabrics, Textile Res. J. 70(8), 675681, (2000). 9. Wong, A. S. W., Li, Y., and Yeung, P. K. W., Neural Network Predictions of Human Psychological Perceptions of Clothing Sensory Comfort, Textile Res. J. 73(1), 3137, (2003). 10. Wong, A. S. W., Li, Y., and Yeung, P. K. W., Predicting Clothing Sensory Comfort with Artificial Intelligence Hybrid Models, Textile Res. J. 74(1), 1319, (2004). 11. Yadav, V. K., and Kothari, V. K., Prediction of Air-Jet Textured Yarn Properties using Statistical Method and Neural Network, Indian J. Text. & Fib. Res., 29, 149156, (2004).

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