STAUBLI FLASH ITMA Asia - October 2018

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1 STAUBLI FLASH ITMA Asia - October 2018 WEAVING PREPARATION FRAME WEAVING JACQUARD WEAVING KNITTING SOLUTIONS Higher degree of automation increases New ranges of cam motions and dobbies Largest format Jacquard machines offer great DEIMO Knitting solutions bring the best customer benefits respond to fast-evolving market trends flexibility cost-benefit ratio for knitters High flexibility answers market demands and rapid trends This issue of Stäubli Flash for ITMA Asia 2018 gives you a fresh look into the ever-expanding world of Stäubli s textile machinery. As soon as you turn the page you will see the announcement of a world premiere: the BEAMPRO reading-in machine for multicoloured yarns. BEAMPRO is installed at the sizing machine and replaces a time-consuming manual process, bringing the mill great economic advantages as well as higher quality in warp production. - Another innovation in the field of weaving preparation is the TIEPRO warp tying machine, whose revolutionary yarn separation method allows fully automatic tying. Also new is an expansion of the model range of the proven SAFIR S30 automatic drawing-in machine (page 3). More and more synthetic fabrics with sophisticated patterns are being produced on water-jet weaving machines. Consequently, Stäubli has expanded its range of high-mount dobbies and perfected the shaft drives for motion transmission (page 4). Stäubli is answering the increasing demands of air-jet weaving mills with the expansion of its range of cam motions (page 5). Along with the associated shaft drives, these units deliver maximum performance with the added benefit of low maintenance cost. The market wants ever more complex, increasingly sophisticated, and denser Jacquard fabrics. This increases the demands on Jacquard machines enormously. How can more than 25,000 warp threads be controlled simultaneously by a single machine? There is only one answer: Stäubli s LXXL Jacquard machine (page 6). If the customer wants assurance that the purchased material is indeed an authentic product of the manufacturer, corresponding branding sewn into the selvedge by a name Jacquard machine can be very useful. See on page 7 how this unit can be easily mounted on the weaving machine even retrofitted. Modern knitting machines produce socks almost 100% automatically, everything except for a small but essential operation. The last detail closing the tip of the toe is now done automatically with Stäubli s D4S device. Learn more about D4S and find out what other solutions Stäubli offers for knitting mills (page 8). Stäubli recognized early on that China would develop into a key market for Stäubli Textile, and responded in good time. Over 20 years ago, Stäubli (Hangzhou) was founded as a strong sales organization as well as production EDITORIAL Dear Reader, Customer expectations for a market leader like Stäubli Textile are high. High too is our level of anticipation as we approach an important textile machinery exhibition such as ITMA ASIA + CITME Will we be presenting the right products? Do they meet the wishes and needs of our customers and markets? Have we set the right priorities? We will not know the answers immediately, but only with time. Inquiries about the needs of the market are questions we ask ourselves continually. Not in our offices, but in talks with you, our customers. We have always endeavoured to know and understand the opinions of our customers, and we continue to do so. This is how innovation becomes reality in the customers best interest. The products we are presenting at our booth at ITMA ASIA + CITME 2018 site. Read more about Stäubli s strong market position in China on the last page of this issue of Stäubli Flash. represent a cross-section of Stäubli Textile s broad range of products. Among them are many innovations and even a world premiere. This may sound impressive, but it s in fact a direct consequence of our commitment to the needs of our customers and the corresponding development of innovative production equipment. We are proud if we can successfully achieve this vision. The ITMA ASIA + CITME 2018 exhibition offers an excellent opportunity for you to benefit from in-depth discussions with us. Visit our booth, tell us what you think of our products, and talk with us about your future needs. I look forward to it. I wish you a successful and interesting visit to ITMA ASIA + CITME Sincerely, Patrick Iltis, CEO Stäubli Textile 1

2 WEAVING PREPARATION Quantum leap at the sizing machine BEAMPRO automatic reading-in machine The production of multicoloured warps by merging various warper beams coloured in the beam dyeing process can be done directly at the sizing machine. The individual warp sheets are separated from each other at the separation field immediately following the sizing process. To maintain the correct colour repeat, the individual coloured yarns must be read into a reed comb before they are wound onto the empty warp beam at the warp beaming machine. The order of the yarns along the beam corresponds exactly to their position in the fabric to be woven. Until now, sorting the yarns into the reed comb has always been done by hand. This task takes 2 to 4 people working several hours per warp. During this time, the sizing machine stands idle. This is where the BEAMPRO automatic reading-in machine excels, bringing users great savings and economic benefits: Productivity and quality improvement in the weaving mill thanks to perfect warp quality: No crossed ends or errors in the colour repeat; the perfect inner structure of the warp along the entire length improves the operating behaviour of the weaving machines. The result is fewer broken yarns and weaving machine stops. The quality of the finished fabrics is enhanced and productivity is improved due to less downtime. BEAMPRO is a higly payable investment for each fancy weaving mill Expanded model series SAFIR S30 The highly successful SAFIR automatic drawing-in system meets the filament weaver s every need. The main applications include protective clothing, awning fabrics, leisure wear, linings, and technical textiles. The SAFIR S30 drawing-in system consists of a mobile drawing-in machine and multiple stationary drawing-in stations. The concept allows maximum flexibility in the setup of the system, even within constricted spaces. Integration into pre-existing production processes can be realised without problem. The SAFIR S30 drawing-in machine enables report-perfect feeding of the warp ends into healds with O-shaped end loops and the reed. Steel or plastic healds are processed with ease. The modular system can be configured and expanded in accordance with the customer s needs and can be operated by a single person. Thanks to continuous monitoring of the automatic processes by AWC, drawing in is faultless and maximum drawing-in rates are achieved. Expanded application areas In order to accommodate the trend for high-density filament fabrics, Stäubli is expanding the number of heald carrier rods from 12 to 16. In addition, a model for warp widths up to 3.60 m will be available in the future. Stäubli customers enjoy the following key economic benefits: Expansion of their product portfolio Production of new types of fabrics Generation of additional business Customer-focused participation in new markets BEAMPRO is ideal for handling cotton and cotton-blend warp sheets. Each yarn sheet may be a single colour or striped with ends of multiple colours. The result is a warp beam whose internal structure, along the entire warp length, shows a yarn order free from crossed ends and is arranged with the exact colour repeat across the entire warp width. The resulting warp beam can be drawn directly into the weaving harness, with no need for a 1:1 lease, with an automatic drawing-in machine from the SAFIR series equipped with the Yarn Repeat Management option. Benefits Minimisation of idle time: Thanks to the high reading-in rates, idle time of the sizing machine is reduced by several hours versus sorting the warp ends by hand. Halving personnel costs: One person is sufficient for the operation of a BEAMPRO reading-in machine. In contrast, up to 4 people are required for several hours for manual sorting of the yarns. Energy cost savings: The production of thermal energy (steam) requires an enormous amount of electrical power even when the sizing machine is idle. The reduced idle time thanks to BEAMPRO delivers a high savings potential per warp beam. Increased productivity: Shorter idle times mean fuller utilization of the sizing machine. Depending on the production requirements, up to 20-30% more warps can be drawn in per shift. Active Warp Control - AWC Active Warp Control (AWC) is in various options a standard feature of every SAFIR drawing-in machine. It is the world s most comprehensive yarn control system, assuring maximum efficiency, drawing-in rates, freedom from defects, and precision of drawn-in warps. Yarn count, colour, and twist direction are monitored and controlled depending on the application and the configuration level. The electronic image processing system provides non-contact monitoring for extremely gentle yarn handling. AWC is designed as a modular system that can be expanded by adding options. It monitors and controls warp sheets with or without a 1:1 lease. With a 1:1 lease, the option Yarn Repeat Detection controls and monitors the entire drawing-in process, and without a 1:1 lease, the option Yarn Repeat Management actively controls yarn separation. The yarns are automatically sorted by colour precisely according to the repeat. This shortens the process of producing multicoloured warps. AWC delivers great economic benefits Security for future investments Increased fabric production with existing weaving machines Flexibility in application Gaining access to new markets Enabling generation of additional orders Reducing production costs BEAMPRO SAFIR S60 After many years of use, our customers are certain that they have made the right investment with their SAFIR automatic drawing-in systems and AWC. AWC very clearly shows its potential with the latest development: Monitoring or fully automatic sorting of S- or Z-twisted yarns has now been added to the functionality scope. As requirements and market conditions continue to change, Stäubli will respond with more functionality enhancements of AWC in the future. UNI-PORT The read in warp beam by BEAMPRO goes directly to an automatic drawingin machine from the SAFIR series for to be drawn into the weaving harness The future of warp tying TIEPRO Stäubli is showing a new warp tying machine featuring extremely fine mechanical precision and supported by high-performance digital technology. Over seventy years of Stäubli s experience in the production of tying machines and tying frames have gone into the completely new design of TIEPRO. TIEPRO is the world s most advanced warp tying machine, featuring exceptional properties: Unique yarn separation process Auto-Reverse function New electronic double-thread detection Short knot ends Few individual components Modular design Good environmental performance Ergonomically designed tying frame SAFIR S30 automatic drawing-in system Warp tying machine TIEPRO Sizing machine Weaving preparation Weaving machine 2 3

3 FRAME WEAVING As the consumption of synthetic fabrics rises, Stäubli steps up to the mark to respond to the fast-evolving market trends in high-speed water-jet weaving. With its innovative technologies and a proactive approach, Stäubli fulfills the large demand - especially in Asia, the main production area for man-made fibres - for faster and more advanced machinery. New range of cam motions for air-jet applications Since 1892, Stäubli has designed and manufactured shedding solutions to best fit weaver needs. To this purpose, our cam motions and dobby solutions are in constant development and evolution. Accordingly, S1691 & S1692 were launched onto the market one year ago to offer a wide range of possibilities for air jet applications. Stäubli responds to fast-evolving market trends in water-jet weaving A well-known water jet range Stäubli has already established a successful and wellknown range of water-jet dobbies. The S3061 & S3062 models and the S2600 series, fitted with the new de82/ de83 harness motions, are adapted to any water-jet application. The electronically controlled S2658 dobby ensures outstanding operational reliability and minimizes maintenance. Modular construction to enhance accessibility Highest quality components Extremely resilient, consistent and reliable Simple to adjust shed opening For water-jet weaving, all our machines are equipped with de82 / de83 harness motions The transmission is a vital link in textile machinery, handling heavy loads and major forces. Thanks to its sealed and patented roller bearing system and the balanced kinematics which decrease vibrations, our new de82/de83 transmissions improve the entire machine performance, reduce the need for maintenance and decrease the mill s operating costs. By selecting the new de82/de83 transmission for water-jet top-mounted dobbies, weavers in all market sectors can take advantage of the advanced Stäubli solution. The new de82 and de83 transmissions are built for very high performance: ❶ Reinforced structure New balanced kinematics, working in opposition ❸ Reinforced drive ❹ Integrated controller Our new range of cam motions includes the S1691 & S1692 for air jet applications Features / Type S1351 S1691 S1692 S1781 Housing Pick repeat 2, 3, 4, 5, 6 picks Levelling No No Mechanical Hydraulical Harness motions Reduced maintenance Lubrication Oil bath Oil bath Oil pump, electronically monitored Advantages for our customers ❶ New mechanical automatic shed levelling device + Automatically level the frames when switched-off + Fully integrated in the machine Cams and bevel gear compatibility + Maintenance cost reduction + Quick change ❸ Lubrication integrated into the housing + Innovative solution + Quick and simple change for oil and filter ❹ ❸...Equipped with proven e32/e33 harness motions technology The e32/e33 transmissions were developed for high speed and heavy load, especially fitted to our latest range of dobbies and cam motions, with a long running life. The maintenance free bearings reduce the oil and grease quantity, decrease the time and cost of maintenance, and increase the reliability of the harness motion. These new cam motions, combined with our S1300 cam motion range and the S1781 model, offer weavers a complete range of solutions adapted to their factory needs. ❹ Unique and strong cover + Optimum sealing to prevent dust penetration + Wear-resistant ❶ Rotary dobby type S2658 completed with a new high speed machine Now Stäubli is launching the new S2678 model, developed especially for water-jet applications in high speed situations. With the new harness motion de82/83, this provides a complete solution for the world s most cutting edge weavers. ❶ ❹ ❸ Protect your investments by using original Stäubli spare parts One of Stäubli s commitments to our customers is guaranteed durability, dependability and performance. That s why we provide a full range of original Stäubli parts for all machines, even many years after purchase. ensures the reliability and productivity of your machines, the safety of your operators, and the quality of your textiles. Enhanced sealing New high performance de82/de83 transmission with water-jet top-mounted dobby type S2678 All Stäubli spare parts are manufactured to the same specifications and certified to the same high quality standard as those in our machinery. Performance Quality Long duration parts and machines A reckless purchase of non-original parts may give you a one-time cost benefit; however, this part may damage machine performance and precision. Productivity Stäubli innovation & service Lubrication web system Reinforced modulator In order to protect your investment, Stäubli offers original parts which ensure longer lifespan, minimized downtime, and flawless function to bring you an outstanding cost-benefit ratio. Using original Stäubli spare parts Secure your investments Reliability and low maintenance Global service Wolrdwide Stäubli teams to advise and support you Rotary dobby type S

4 JACQUARD WEAVING A personal signature adds value on high-end fabrics With over a century of experience in textile engineering, Stäubli is confident of its capacity to manufacture firstclass Jacquard machines. Always receptive to the market demands of weavers, retailers and consumers, Staubli has adapted to the digital era, where style is fleeting, often introduced by the latest celebrity, and technology is required to adapt at great speed to short-lived trends. Consumers are increasingly interested in personal identity and unique creativity. Stäubli s newest LXXL Jacquard machine offers weavers unlimited possibilities for developing large sophisticated patterns and unique designs. Largest format Jacquard machines offer great flexibility In order to enhance the value of a woven fabric and to prevent counterfeiting, having the brand name, logo or label on selvedge is becoming a very common requirement in China. This applies mainly to luxury woollen and cashmere textiles that tailors use to make high-fashion suits and other apparel. The CX172/CX182 name selvedge Jacquard machines have the outstanding features and high quality standard of all Stäubli machines. They are built to deliver top performance in premier fabrics with a personalized signature for your customer. Driven by separate servo motor, no extra modification to the weaving machine is required Integral harness independent of the weaving machine Proven technology of Stäubli MX module ensures accurate hook selection and precise shed opening Fully intelligent and user friendly control system JC7N or DC1 which is able to control up to nine CX 172 or CX 182 Jacquard heads each with up to 192 hooks Precise, high-speed weaving and minimum downtime increase productivity Stäubli has forged strong partnerships with many major market players in the weaving industry, thereby gaining extensive know-how and expertise of their machines. The CX172/CX182 Jacquard machines are perfectly compatible with all weaving machines and Stäubli R&D department works tirelessly to update and optimize adaptations, offering to weavers optimum functionality and the best possible results. CX 172 Jacquard machine LXXL Jacquard machine Sized up to 25,600 hooks and designed for very high density fabrics, the new LXXL is also dedicated to very large width weaving. The LXXL is particularly suitable for luxury and high quality fabrics for clothing, upholstery, silk-weaving, bed linen and covers. Formats of up to 51,200 hooks can be achieved by combining two machines in tandem, pushing the boundaries of innovation and creation to a whole new level. To achieve a high degree of control and connectivity, the LXXL is equipped with a whole new NOEMI electronics. Simplicity of use and high speed data transmissions contribute to making maintenance easier. The new electronics combined with thermos-regulated cooling fans ensure a stable temperature inside the machine, allowing higher component lifetime and significantly reducing energy consumption. With High Performance Kit available, it s possible to weave heavier articles at greater speed. In addition, the Independent Stäubli Drive replaces the traditional shaft transmission with a servomotor to deal with highly loaded Jacquard machines. MX module ensures an accurate hook selection and works flawlessly even in the most stressful environments or extreme temperatures. Thanks to the reliability of our Jacquard machines, our expertise and skilled teams, Stäubli is present in every leading-edge field: automobile, aviation, agrotechnology. On-demand and dedicated solutions can be developed for even our most inventive customers. CX 172 / CX 182 LX 12 / LX 32 / LX 62 DX LX 2493 SX / LX / LXL / UNIVAL 100 Registered design - Stäubli protects the aesthetic appearance of its products SX V / LX V / LXL V Name selvedges Ribbons Labels Flat fabric Terry towel Technical fabric Carpet Velvet fabric Stäubli harness Naturally, the LXXL Jacquard machine benefits from the latest Stäubli innovations and technologies in the Jacquard field. The balanced kinematics with the two coaxial shafts controlled by complementary cams also benefit the LXXL to ensure accurate shed geometry and absolutely vibration-free operation. Like all the Stäubli s Jacquard machines, the LXXL has been carefully developed to deliver high level performances with easy maintenance. In addition to its smart design - low friction engineering, optimum sealing, lubricated-for-life bearings and strong components drastically reduce production breakdowns and costs. Independent Stäubli Drive Maximum performance can be achieved by choosing Stäubli s custom-configured harnesses. Stäubli s springs are carefully optimized to reduce loads on machines, making possible a perfect weaving. The MX module is the heart of our machines and a main contributor to the reliability and long lifetime of Stäubli Jacquard machines. Thanks to its dimensionally stable composite materials and sealed read-in chamber, the LXL Jacquard machine The innovative Stäubli machines resemble no others and their Design is one of the symbols of Stäubli high quality. For more than 15 years Stäubli has registered Design of its textile machines and ten Stäubli Jacquard machine formats are currently protected by Design patents in force in China. Selling, for example, a machine that copies the appearance of a Stäubli machine, constitutes Design patent infringement and will be punished by law. 6 7

5 KNITTING SOLUTIONS Best CBR, quick ROI for sock manufacturers A final touch for automated sock production - automatic toe linking drastically reduces production time and grants a quick return on investment (ROI) for sock manufacturers. In the knitting industry, the most essential challenges are close pricing competition, demand for high quality and rapid trend reactivity. Stäubli s D4S toe linking device (patents pending) answers the knitters expectations. The device is directly mounted on sock machines with a diameter from 3 ½ to 4 ½ inches and from 8 to 19 gauge. It independently sews the toe closed while the sock knitting machine simultaneously produces the next sock. The precise and high quality automatic toe linking combines functionality and comfort for the end-user. A complete solution for quick reaction to market demands Nowadays, knitters are more conscious of having machines equipped with high performance, powerful, user-friendly controllers to ensure efficient sock production alongside attractive features for different styles and various designs. Stäubli offers a complete solution with the electronic controller 2900SL, a programming system Styler for knitting patterns as well as DData for process monitoring and data recording during knitting. seamless garments. Thanks to its key features: easy customization, configuration and programming, the customer is able to react quickly to market demands and constantly deliver competitive final products. Stäubli s fully automated knitting process will bring manufacturers a huge cost-benefit ratio (CBR) and will delight their customers. As no operator intervention is required, the D4S offers a highly efficient automatic toe close process, decreasing the machine s idle time and reducing the waste yarns. Stäubli s controller 2900SL for circular knitting machines, can be used for the production of socks, tights, and in the medium to high diameter range underwear and Stäubli D4S toe linking device Cutting-edge technology rooted in China for 20 years Since 1892 the Stäubli Group has expanded both technologically and geographically. After more than 120 years of innovation, the Stäubli Group today is a global mechatronics solution provider with three dedicated activities: Textile, Connectors and Robotics. The importance and dynamic development of the Chinese market motivated the Group to establish its first Asian manufacturing plant in China. Stäubli (Hangzhou) Mechatronic Co. Ltd was created in 1997 and dedicated to the production, sales and R&D of advanced electro-mechanical equipment and machinery, as well as providing reliable service and support for the Chinese market. sales engineers are all over the country, ensuring a quick response to customers. Sales, technical support, training and after-sales service meet customer needs at all levels. With our cutting-edge mechatronics products and solutions which improve the production efficiency of various industrial enterprises, we strive to achieve a win-win situation for customers, employees and stakeholders. Over the past 20 years, Stäubli Hangzhou has worked hard to be at the forefront of their field. Looking to the future, we are confident that its 600 employees will fulfill our promises to customers. Stäubli Flash Stäubli Flash is published by Stäubli, Textile Division, Communication Department, Poststr. 5, CH-8808 Pfäffikon SZ, Switzerland Editor s address: textile.mkg@staubli.com Photos: Shutterstock, Fotolia, Stäubli, Yann GEOFFRAY Staubli is a trademark of Stäubli International AG, registered in Switzerland and other countries. Stäubli, October 2018 Stäubli offers training to its customers that is adapted to their specific needs and which can be conducted either at designated locations or at the Stäubli Asia Training Center in Hangzhou. In order to offer technical customer support, as well as excellent service in close proximity, Stäubli has set up offices in twelve cities: Beijing, Shanghai, Guangzhou, Wuhan, Suzhou, Xi an, Chongqing, Shenyang, Nanjing, Tianjin, Shenzhen and Chengdu. Our technical experts and The plant of Stäubli Hangzhou Stäubli Carpet Flash You are interested in weaving rugs or wall to wall carpets? Please ask for our Stäubli Carpet Flash.