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--Dahao High-efficiency All-servo
Computerized Control System |
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for Embroidery Machine |
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Background |
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Generally, there are two indexes on measuring the performance of a computerized
embroidery machine, which are productivity and product quality. During the
over-20-year’s development of embroidery machine industry in China, both
manufacturers of computerized controller and the producers of machine have been
trying their best to enhance these two indexes. Meanwhile as a kind of tool for
production, the computerized embroidery machines have the conflict between its
efficiency and its production cost featured in the middle-low end market. That
is why the high-speed computerized embroidery machine was so popular when it had
been promoted to the market. Especially for the recent years, no matter the
domestic manufacturers or the foreign producers have been breaking the
limitation of the speed for computerized embroidery machine. The speed has been
increased from 1000rpm to 1300rpm, then to a new stage speed at 1500rpm.
However, along with the increase of speed, the cost of the embroidery machine
increases continuously. Because the traditional mechanism and the material
performance are unable to meet the requirements against the wear-out under the
high speed any longer. In order to overcome the working noise and vibration
brought by the high speed running, the manufacturers have to improve the
mechanism, or to use the better material, even to attach the expensive
shock-absorbing device with special structure, all of which continuously weaken
the performance-price ratio of high speed machine. Besides that, when the speed
of main shaft increases, the instant tension undertaken by thread is increased
too, which also set a high requirement on the strength and
temperature-resistance of the thread. If the user uses the normal thread or the
unqualified thread, the rate for thread-breakage will rise, and the quality of
embroidery will be lowering. That is the main reason to explain why the
high-speed machines usually have the problem of high thread-breakage rate.
Therefore, how to enhance the efficiency of the embroidery machine within the
acceptable cost has become an important task in the controller design. |
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All-servo High-efficiency Machine ---- to
achieve higher efficiency with same cost |
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The all-servo high-efficiency
machine is the new conception under this background. In common circumstance, the
speed used to describe a machine is the max speed during its working. For an
example, if the speed of a machine is said at 1000rpm, it doesn’t mean that the
machine works at 1000 rpm at all the time. The computerized controller will
adjust the speed according to the stitch length. When the stitch length is too
large, the main shaft speed will decrease to a lower level so as to meet the
needs at moving frame. So there are 3 parameters to describe the efficiency of
machine, including the Max Speed, Min Speed and the shift stitch length, among
which the max speed and the min speed determine the speed range of the this
machine while the shift stitch length determines the key stitch length for
lowering the speed. When stitch length of the existing pattern is over the shift
stitch length, the controller will lower the speed so as to make sure the frame
has the enough time to move to the proper position. Obviously, if we want to
enhance the efficiency, we can increase the min speed and the shift stitch
length instead of just enhancing the max speed. |
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The traditional computerized
embroidery machine using step motor to drive frame usually has its max speed at
750rpm. When the stitch length is over 5 mm, due to the functional limitation of
step motor, the controller system will lower the main-shaft speed so as to make
sure that the frame has enough time to move to the proper position. However,
along with the application of the servo motor on the frame driving system, this
system will break this bottleneck. Compared with the stepping motor system, the
servo motor features the high speed, strong load capacity and large output
torque. In the circumstance of keeping the mechanism away from the critical
changes, the system can improve its shift stitch length to 8mm and the min speed
from 400rpm to 750rpm. Then for the most patterns, the machine will keep its
speed at a high level while keeping its highest speed remained. And thanks to
the stable running of the servo system, the vibration, noise and wear-out of the
machine will also be kept in a tolerable range. |
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In this way, not only the cost
of machine will not increase by large margin, but also the shift stitch length
will be increased by 60%, which covers the most stitch lengths in patterns.
Because of the usage of servo system, the frame is running more stable and the
noise is lowered. Without the large increase on the speed, the machine will keep
its wear-out, requirements on thread and thread-breakage rate in a reasonable
level. |
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The computerized embroidery
machine is a combination of the machine and the computerized controller. The
traditional ones just depend on the mechanical performance to increase the
main-shaft speed, thus to enhance the productivity. That is why the Mechanical
Guide of High-speed Machine was made. If in the processes of designing and
installing the high speed machine, the manufacturer fails to update the key
components, the performance of the whole machine will be affected and the
embroidery effect will be lower than the expected, or even the lifetime of
machine will be shortened by a large margin. The brought vibration and noise
will also exceed the tolerable range. |
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In contrary, the high efficiency
machine doesn’t depend on the mechanical device so much, thus gives full play to
the computerized controller. By using the servo frame drive system and the new
control method, the machine will only need some tiny changes to increase its
efficiency by a large margin. |
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Performance of All-servo High-efficiency Machine |
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Technical Index: Max speed:
850rpm; Min speed: 700rpm; shift stitch length: 8.0mm. |
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Mechanical Attachment：Normal
head (solenoid lock head), normal drive guide trail and Dahao servo drive
(frame). |
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The comparison between flat embroidery
machine (normal stepping motor) and high-efficiency embroidery machine： |
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Stitch Length |
Flat Embroidery Machine (Step Motor) |
All-servo High-efficiency
Embroidery Machine |
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0.1~1.0 |
750 |
850 |
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1.1~2.0 |
750 |
850 |
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2.1~3.0 |
750 |
850 |
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3.1~4.0 |
750 |
850 |
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4.1~5.0 |
750 |
850 |
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5.1~6.0 |
700 |
850 |
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6.1~7.0 |
660 |
850 |
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7.1~8.0 |
610 |
850 |
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8.1~9.0 |
570 |
780 |
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9.1~10.0 |
530 |
780 |
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10.1~11.0 |
480 |
720 |
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11.1~12.0 |
440 |
720 |
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12.1~12.7 |
400 |
700 |
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Prospect of Market |
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1、Suitable for Market of
Shell Fabric Processing (Functions Strengthened according to the Requirement of
Indian Market) |
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Efficiency is performance index
mostly focused by the market of shell fabric processing. Because nowadays the
labor cost is increasing, the higher efficiency means the higher profit. |
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Additionally, the all-servo high-efficiency machine also features the sound
adaptability to the large frame. |
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After
the test, the high-efficiency machine can successfully meet the requirements of
Indian market on large stroke and big breadth (sometimes the stroke in Y
direction is 1300mm, and the drive frame has 6 tracks). |
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2、High-efficiency Machine
Helps You Step Into Garment Processing Market |
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The all-servo high–efficiency
machine keeps the sound adaptability of the all servo models to the quality of
embroidery on one hand, and on the other hand, by adjusting the parameters, it
also can assure the accuracy of each stitch length and be adjusted according to
the special requirement on the embroidery from client. |
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By improving the frame-moving
algorithm, the all-servo high-efficiency machine enables to realize the sounder
small letter embroidery and tatami embroidery. By using the computer parameters,
user can adjust the embroidery effectively according to his special
requirements. |
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The Type of Computer |
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At last, we welcome you to try
our high-efficiency all-servo computerized control system. At present, this
function is available on computer 316, 366, C18 and C88. You are welcomed to
have a try at it. |
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For any technical problem,
please contact our engineer Zhouyou at 13911167195 |
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Beijing Xingdahao Technology Co., Ltd Emb. Controller Dpt |
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