“Challenging applications with Staubli products”

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Staying permanently at the forefront with high-end products requires continual development. This applies to both the weaving industry and machine manufacturers, and it requires broad market knowledge and excellent understanding of customer needs. Machine manufacturers need to continuously adapt and further develop their products to meet evolving needs and new requirements, just as weaving mills are constantly creating new textiles and applications.

At ITMA Asia 2014, Staubli demonstrated the production of lining fabric on the world ‘s most modern Jacquard machine, the type SX, in conjunction with a water-jet weaving machine operating at a rate of over 1000 weft insertions per minute. A special feature of this set-up is that the weaving machine and the Jacquard machine are both operated by individual electronically synchronized drives.

The third generation of Staubli’s rotary dobbies, the 83000 series, is without question among the world’s top performing frame drive systems. Increasingly more filament-weaving mills are taking advantage of increasing automation in weaving preparation and benefitting from the advantages of the SAFIR 830 automatic drawing-in machine.

Jacquard Weaving

New Jacquard technologies – for new opportunities

Staubli Textile, founded in 1892, and today a leading manufacturer of shedding motion systems, presented another world premier: a Jacquard machine with independent drive running at 1 ,000 rpm shown on a water-jet weaving machine.

Continually pushing towards new horizons to deliver new opportunities and benefits to Jacquard weavers, Staubli presents two major innovations: the first is an independent drive system for any type Staubli Jacquard machine, the second a Jacquard machine installation on a waterjet weaving machine.

At ITMA Asia 2014, visitors saw for the first time a water-jet weaving machine in operation with a Staubli type SX Jacquard machine. This installation runs at a speed of 1,000 rpm, using a specifically developed motor from the Staubli Group to independently drive the Jacquard machine. Such a high-performance installation challenges every system component and is particularly demanding on the harness.

Staubli harnesses are widely appreciated by weavers for their levelling features and the perfectly balanced quality of the components, which delivers high performance and durability. Due to specific environmental conditions, water-jet weaving requires that the harness components possess certain particular characteristics. Staubli ensures such a high level of quality by using frames of aluminium, stainless heddles and springs, and special treatment of the harness cords and the comber board.

Staubli’s experience, know-how, and high technology used in its products enables mills to weave at high speeds, with high efficiency, and with the required shed geometry for any kind of fabric. In Jacquard technology, Staubli equips all types of weaving machines with any type of weft insertion system: rapier, projectile, air, or water.

Staubli introduced the type SX Jacquard machine four years ago at ITMA ASIA 2010. The machine was a main attraction of the exhibition, running at over 1,300 rpm on an air-jet weaving machine. Meanwhile, several thousand SX units, with either 1408 or 2688 hooks, have been installed in weaving mills around the world, producing upholstery, curtain, cloth, terry towel, label, silk, car seat, velvet, and many other kind of fabric to the full satisfaction of users.

The success of the SX Jacquard machine is based on a combination of key factors: high performance and .high reliability, compactness, resistance to harsh environments, and maintenance-free mechanics. Like no other Jacquard machine, the SX is sealed against dust and has an effective filtration and ventilation system. This results in almost no machine downtime, which is a decisive advantage for today’s weavers who demand high efficiency. Along with the entire range of Staubli’s Jacquard machines, the electronics of the SX have been further developed and brought up to the state of the art. This includes the JC- Jacquard controller, which allows user-friendly interaction and programming, and the M6 module that, controls the harness movement.

Independent transmission systems

Staubli has been developing a range of independent drive systems that can be combined with any type of Staubli Jacquard machine with any number of hooks. These drive systems enable special setups that are impossible with conventional transmissions, such as shafts, chains, or belts.

This breakthrough opens new opportunities for weavers who have special needs or ideas for new ways of weaving.

For example:

• Combining a Jacquard machine and a cam motion or dobby on a single weaving machine

• Installing a Jacquard machine on a weaving machine with no mechanical transmission to the Jacquard machine

• Installing a Jacquard machine on a weaving machine whose drive is not strong enough to run the Jacquard machine

• Replacing the chain or belt transmission of an existing installation

• Using several Jacquard machine heads on one weaving machine

• Pick finding running independently of the weaving machine

• Independent drive of the Jacquard and the weaving machine (pick insertion and reed movement independent from the Jacquard movement)

• Easily offsetting the Jacquard machine from the weaving machine.

Have you been wrestling with such a challenge in your mill? Talk about it with Staubli Textile. We might just have the ideal solution for you.

Weaving terry towel: Never simple, but easy with Staubli Jacquard installations

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An electronic Jacquard machine allows many ways to set the shed openings, and a harness can be levelled either this way or the other. However, achieving optimal quality when weaving a specific type of fabric on a specific weaving machine requires suitable equipment and proper setting of these parameters.

When weaving terry towels, shed geometry and harness levelling is of particular importance, as the quality of the woven terry towels is significantly increased when the shed geometry for the pile and the ground is set individually. With a Jacquard machine plus harness provided by Staubli, the installation is not only fitted to the weaving machine’s requirements but is optimally adapted to the weaver’s needs. This means no more time-consuming settings during start-up in the weaving mill and no further or approximate mechanical adjustments.

If several terry installations provided by Staubli are to be realized simultaneously in a mill, the weaver can be sure that they are absolutely equal and uniquely dedicated to his specific operation. This service is possible because Staubli manufactures both the Jacquard machine and the harness and, thanks to very close collaboration with all major weaving machine manufacturers, has the know-how to determine the right shed for the articles to be woven by its customers.

Each Staubli customer is individual, and the wishes and needs of each weaving mill are unique and particular. This is why Staubli’s Jacquard installations with harnesses are tailored to the customer’s requirements and coordinated with the weaving machine’s shed geometry. Staubli draws on over 100 years of experience as a specialist for shed opening for any kind of fabric. Terry weavers and many others can count on and benefit from this competence.

Name selvedges in demand in China

The trend to label fabrics woven in China is becoming more and more widespread. To give a more personal note especially to high-end fabrics, demanding customers want individual inscriptions of their name or at least the brand name of the fabric on the selvedge of the fabric. This mainly applies to luxury woollen and cashmere textiles that tailors use to make high-fashion suits and other apparel.

This is where the perfect tool for lettering selvedges enters the picture: Staubli’s name Jacquard machine CX 172. Thanks to its modular concept, this machine can be easily adapted to any kind of weaving machine, whether newly purchased or already in use. With autonomous drive and fixation, the ex 172 can be quickly fit, and it operates at all required speeds with full efficiency. The results are personalized, perfectly woven-in selvedge inscriptions that emphasize the individuality and value of a fabric.

To suit any use, the CX 172 is available with either 64 or 80 hooks per head, which are managed by and programmed through the controller DC1 and JC7N. It features the same outstanding quality standard of all Staubli machines – built to deliver top performance.

Use the CX 172 to label your high-quality fabrics, add value of your products, and give your customers a name they can count on!

Carpet Weaving

New design options in carpet weaving up to 5.3 m wide with the advanced ALPHA series

With the highest flexibility in design options and weaving widths up to 5.3 m, the new ALPHA 500 UNIVERSAL carpet weaving machine from Schonherr includes all proven features of the ALPHA 400 and delivers increased productivity while handling different carpet sizes.

Proven efficiency in carpet production

The ALPHA series has been well proven at numerous weaving mills and is known for efficient production of area rugs and wall -to-wall carpets for the residential, contract, and transportation sectors.

New level of flexibility

The highest production of standard carpets with unbeatable qualities is possible with the ALPHA 400 EASYSYSTEM. This carpet weaving machine features essential state-of-the-art technology such as a real three-position Jacquard machine, servo- controlled cutting device with toothed belt, cam disk dobby, liquid cooling system, and other additional options offering even more flexibility.

Different carpet qualities

On the ALPHA 400 UNIVERSAL each size of order can be processed very quickly. Different carpet qualities are possible by simply programming the parameters; e.g. 2-shot, 3-shot, and single-shot bindings can be woven on the same machine and changed by simply pushing a button.

Reed density up to 1020/m

Reed densities up to 1020/m or even higher are becoming standard. Today the ALPHA 400 INNOVATION as well as the ALPHA 400 UNIVERSAL master even higher reed densities up to 1020/8.

With the servo cutting device, the rotary dobby type 2688, or the servo-controlled UNIVAL 500T, carpets are produced with excellent surfaces, the highest resolution, no mixed contours, and a very clear carpet back.

Area rugs and wall-to-wall carpets with higher speed; loop carpets with weft effect

With the ALPHA 400 SINGLELOOP, area rugs and wall-to-wall products for different applications can be woven at production speeds two to three times higher than with wire loom technology. Loop and flatweave structures as well as combinations can be realized. This machine is also well known for the production of loop carpets with weft effects or flat-woven Kel im rugs featuring Magic Weft Effect.

New options for designers and carpet weavers

The Multi Weft Selector allows the insertion of up to six different weft yarns in the same fabric, which offers endless possibilities and new options for designers and carpet weavers. Because of its modular design, a weaving machine can be equipped with any requi red number of selectors: 2+2, 2+4, 3+3, and so on, up to a maximum of 6+6 different fillings.

New carpet technologies such as Magic Weft Effect and the next generation, “Magic Weft Effect 3” are possible thanks to the Multi Weft Selector. Different wefts are visible next to each other at the same pick line, enabling “free Jacquard patterning” with up to 6 weft yarns. The carpet world has responded to the resulting marvellous patterns with great enthusiasm.

“Magic Shadow Effect” is newly launched. A uni-colour pattern emerges through · different angles and creates new possibilities for modern living styles. Carpets woven with 1020 reed/m, eight colours, and combined with “Traditional Carpet Effect” appear to be hand-knotted. The difference to man-made products is noticeable only to experts. 4m weaving width is possible.

Frame Weaving

Progressive frame driving systems

Quality, flexibility, and efficiency remain prerequisites for every successful weaving operation. Fabric markets have become more competitive than ever, and demanding customers are setting the pace for suppliers. The successful weaving mill must be a responsive and well-managed operation that produces fabric on highly competitive weaving machines. To get the most out of the modern weaving mill, Staubli equips weaving machines with adapted frame-driving systems. For shed formation optimised to the mill’s specific needs, the user can choose from Staubli’s wide range of cam motions and electronic dobbies. These have all been built to state-of-the-art standards and the newest machines feature the very latest technological developments.

Staubli’s third generation of rotary dobbies for different configurations

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The rotary dobby, a revolutionary machine invented by Staubli many years ago, has been steadily developed further, and the third generation of electronic rotary dobbies has been introduced recently. This dobby generation has significant advantages over previous models and brings astounding benefits to weavers.

S3000 I S3200 electronic rotary dobby family

The heart of every dobby is the locking system. The family of 83000 I 83200 electronic dobbies features an improved locking system that provides enhanced security for selection of the heald frames. Together with a new electronic reading-in system, this leads to higher performance and superior reliability – and consequently to improved operating results.

Impressive key features are:

• New locking system with advanced security for heald frame selection

• Built-in control unit

• Reduced noise and vibration

• Reduced housing size

• New high-performance drive system for the harness motion

• Less maintenance.

Made for high demands

High-quality dobbies continue to play an essential part in fabric production on competitive weaving machines. While the new 83000 I 83200 is now 8taubli’s state-of-the-art dobby family, the preceding series 2600 I 2800 is still being offered for use with certain weaving machine models and for certain applications. 8taubli’s reliable shedding systems are not limited to dobbies, but also include cam motions for a broad application range. Both meet the high demands of today’s weaving operations.

Adapted range of cam motions

To succeed in today’s competitive market, weaving with cam motions must provide great flexibility and high performance. Staubli’s range of cam motions has been further developed to meet the latest requirements of modern weaving machines. The fu ll line of 8taubli cam motions now includes the types 1671 /1681/ 1781. These advanced machines are equipped with a high-performance cam-and-lever assembly and a broad rang of symmetrical and asymmetrical cams.

Weaving preparation

SAFIR S30 – The benchmark for automatic drawing in of filament yarns

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With the recent introduction of the SAFIR S30 automatic drawing-in machine, which is especially suited to the filament market, Staubli is successfully following up the era of DELTA drawing-in machines. The SAFIR S30 is a mobile drawing-in machine that travels along the stationary warp beam as it draws the filament yarn into the healds and reed. This new method of operation has proven highly advantageous.

A flexible concept

The concept allows flexible layout planning of the drawing-in room. Thanks to the mobility of the SAFIR S30, many different types of equipment arrangements are possible. Depending on the existing situation, the stationary warp beam locations can be arranged in linear succession or e.g. opposite one another. Uform arrangements are also possible, in case the existing context requires.

This establishes a clear spatial separation between the actual drawing-in process and the delivery and removal of the warp beams.

Optimal material flows to prevent logistics glitches and to improve workplace safety are important to users. The compactness and low height of the overall drawing-in machine enhance good ergonomic working conditions. The capability to draw in the healds with closed end eyes precisely and according the repeat pattern on up to 12 heald carrier rods covers every need, especially for filament weaving mills.

High drawing in rates

Staubli’s customers expect from the automatic drawing-in specialist convincingly high performance and error-free drawing in. The SAFIR S30 has been in successful use for over two years in China, Taiwan, Japan and other Southeast

Asian markets, and the production figures achieved in practice give concrete proof: Depending on the application, the drawing-in capacity significantly exceeds 200,000 ends per 24 hours. And this, nota bene, is the standard.

Also for high-end applications

Thanks to the optimized yarn separation principle, the processing of ultrafine filament yarns (mono- or multifilament) presents no problem. Filament warps with or without lease and with a warp density exceeding 100 yarns per centimetre, e.g. for a two-thread reed stitch, are no problem to draw in according to the desired repeat pattern.

Great savings potential

Optimum integration of all components of the drawing-in machine results in an extremely low error rate. Under normal conditions, this measures at the most 0.5 errors per 1,000 draw-ins. Thanks to this reliability, it is possible for just one person to operate and monitor up to three drawing-in machines. This very good functional behaviour directly influences the entire weaving mill. Users report significant improvement of the utilization rate of their weaving machines – up to 10% – in comparison with manual drawing in. The use of plastic healds instead of steel ones lends additional savings. The rapid and uncomplicated changing to other heald lengths or reed density greatly reduces setup times.

High-tech for sophisticated yarn material

Yarn materials and woven fabrics that are increasingly more diverse and more delicate significantly increase the demands on thread separation. The SAFIR S30 handles this task without the use of conventional separation needles; rather, with suction nozzle or lease tubes, depending on the physical properties of the warp.

If the warp sheet has a lease, the yarns are separated from the yarn layer by means of lease tubes. If no lease is present, the vacuum gripper is used. Thus, for example, even warps with mixed yarn fineness within the same warp sheet can be drawn in.

A layer separation unit for two separate warp layers is available as an option. This allows drawing in yarns from two warp layers with no lease, which is especially useful for complex fabrics. It also allows problem-free mixing of different materials while ensuring accurate sequences. The SAFIR S30 even draws in S-/Z yarns precisely as required by the programmed repeat.

Proven economic benefit

The very high drawing-in rate in combination with the extremely low error rates results in the greatest flexibility in the scheduling of the warp beams and weaving machines. The extremely short setup time of the SAFIR $30 enables swift response to short-notice changes in the market. Flexibility in the processing of various applications while simultaneously reducing second-quality output as well as the other advantages already mentioned lead to high cost effectiveness. Calculations show that an attractive return on investment is possible – vvithin less than two years.

High customer satisfaction

In the short time since the market introduction of the SAFIR S30, the machine has convincingly proven itself in filament weaving mills. This is evidenced by the fast-growing number of installed systems and the growing interest of customers in new markets. For Staubli this is reassuring confirmation that the new concept chosen for this drawing-in machine is the correct one for the targeted customer segment.

From the group

New knitting-machine controller type 2900 S Staubli Group member DEIMO, based in Italy, is committed to the development of advanced electronic systems and components primarily for textile machinery.

The latest model in its range of controllers – the type 2900 S – serves as an electronic controller for circular knitting machines. These machines are used to produce hosiery goods, socks, woollen stockings, pantyhose, and medium-tolarge diameter goods in various sectors such as seamless, underwear, outerwear, garments, home textiles, and automotive. The 2900 S includes the new CAD graphic software D-Styler, which allows easy programming of patterns. It also includes the data system D-Data for interfacing, monitoring, and remote controlling the machine. Its most innovative electronic technologies includes a user interface with multi- language colour LCD, LAN/Ethernet connection, CAN-bus connection for control of remote peripherals, and a fully digital CAN-bus servo-drive interface. Driven by its Linux-based operating system and DEIMO’s powerful software tools, the 2900′ S allows elegant and precise control of a wide range of circular knitting machines. It has met with full customer satisfaction.

DEIMO is a competent and trusted partner for any supplier of textile machines that require sophisticated, customized, and reliable control solutions for their products. Bring us your special requirements and we will engineer an outstanding solution.

Staubli’s intellectual property rights strongly defended

Staubli recently won another lawsuit filed in Suzhou regarding patentinfringement of a dobby machine. The favourable verdict was issued at the appeals stage by the Jiangshu Province High Court with the award of monetary damages. The Chinese legal system has been continually increasing its level of protection of intellectual property rights, issuing severe verdicts. Increasingly effective laws and legal tools allow Staubli to more strongly defend its rights before courts and administrative authorities. This strengthens Staubli’s resolve to contest every single case of infringement.

The benefits of using original spare parts

Staubli machines are internationally renowned for high reliability and precision. This is because Staubli fabricates its parts and machines to exacting tolerances, using only the best materials and highly sophisticated manufacturing processes. During daily use in the weaving mill, ·the moving parts of these machines withstand high ioads and stress.

Inevitably, a worn part will require replacement someday. It makes sense to use only original Staubli parts, because only these are of the same quality and specifications as all others in your machine. This is an important way to ·preserve the safety, value, performance, efficiency, and reliability of your machine – and thus ensure the performance of your mill. We count on your understanding that the use of unauthorized or non-original parts voids your warranty. Any defect or damage caused by such use can not be covered by Staubli.

Interactive spare parts e-catalogue

The easiest way to order spare parts from Staubli is by using our on-line spare parts catalogue. Simply enter the serial number of your Staubli machine and you will be guided through the ordering process. You are welcome to visit the e-catalogue at www.staubli-catalog.com and set up your own account.

Staubli in China

European technology taking root in China

In 1997 the Staubli Group opened its first industrial manufacturing site outside Europe. Based in Hangzhou, China, Staubli (Hangzhou) Mechatronic Co., Ltd is focused on the production, sales and service, applications, and customised solutions in precision mechatronics. The company is committed to providing quality products and advanced solutions for the Chinese market.

After more than a decade of aiming for excellence, Staubli Hangzhou has grown into a high-tech company, providing – ali of Siaublt’s products, innovative technology, and comprehensive services to the Chinese market. In keeping with the Group’s tradition of excellence and spirit of professionalism, we assiduously improve the quality, efficiency, and safety of our products. We focus on close cooperation with our partners to meet the needs of various industries for high-tech equipment and solutions. China’s industries are in a period of transition involving technological renewal and industrial upgrading aiming towards high efficiency, lower carbon emissions, and intell igent automated manufacturing. We firmly believe that Staubli’s high-tech products and solutions offer outstanding benefits and returns to our customers.

Supply of high-performance, first-class products

Our range of textile machinery covers rotary electronic dobbies, electronic jacquard machines, cam motions, and textile machinery controllers. Thousands of Staubli textile machines and systems are currently operating in textile factories throughout China. They are highly efficient, reliable, and easy to operate, helping customers raise their efficiency and lower their production costs.

High-quality and comprehensive services

We provide training at all levels in the application and maintenance of products in the fields Textile, Connectors, and Robotics. Customers can undergo training at our training centre in Hangzhou and can also take advantage of Staubli’s high-quality services at designated sites.

Broad geographic coverage for quick customer response

To make sure that our many customers will have convenient access to the latest technology, we have sites in Hangzhou, Beijing, Shanghai, Guangzhou, Wuhan, Xi ‘an, Chongqing, Shenyang, Suzhou, and Nanjing. Our technical experts and sales engineers are stationed throughout China. Thus, our professional team can swiftly respond to customers’ needs for sales, technical support, training, and after-sales service.

Carpet customers are followed by Beijing Shengdisen Science & Trading Co. , Ltd. Wfio – contmuously serves as the Schonherr representative in China, building up a strong network for sales and service for ALPHA carpet weaving systems.

Staubli – fast moving technology in three divisions

Staubli was founded in 1892 as a small workshop in Horgen, near Zurich. Through its high-quality products Staubli  became one of the world’s leading manufacturers of textile machinery. Today, Staubli is an innovative mechatronics solution provider with three dedicated divisions: Textile machinery, Connectors and Robotics.

Staubli, with head offices in Ptaffikon, Switzerland, employs over 4,000 people and is active in major global markets. With its Multi-Contact, Sch6nherr, and DEIMO brands, the Group maintains a presence in 25 countries and is represented by agents in 50 further countries.

ROBOTICS

Staubli Robots offers high productivity and precision, providing preferred solutions for many industries. The comprehensive product range includes small 4-axis SCARAs as well as heavyduty robots operating with payloads of up to 250 kg, completed by controllers, software, and professional applications.

CONNECTORS

As a leading manufacturer of quickconnector systems, Staubli provides connection solutions for all types of flu ids, gases, and electrical circuits. The products include single and multiple connectors, tool changers, quick-mould-change systems and combine performance, quality, safety, dependability, and durability.