With improved AI based sensors for cross seam and selvedge thread detection as well as its latest cleaning concepts, Erhardt+Leimer is entering a new era of automation. In addition, the new connectivity between machines and E+L components opens up a new dimension in data management. A subsidiary with a highly trained service team as well as a production site represents Erhardt+Leimer in India.
AI sensors for smart production: ELSEAMTEX and ELWARP
The E+L seam sensor ELSEAMTEX optically detects any kind of seam on printed or colored webs. Its software uses artificial intelligence to detect cross seams with 99.9% reliability. In addition to an LED light and a matrix camera with lens, the sensor also includes a WLAN card for reliable communication with any mobile device. If the camera detects a cross-seam during continuous production, a digital output can, for example, open calander rollers or protect shearing knives and digital printing heads. As a very sophisticated feature, seams can be tested offline using the E+L AI app (free of charge available in all the relevant App stores).
Since the AI database has been growing for nearly two years now, the sensor‘s knowledge is close to perfection. However, the database is constantly updated with each new seam to ensure that ELSEAMTEX can protect the corresponding machines, improve the quality of the final product and reduce costs even better.
In many cases, the textile web is cut on both selvedges along the warp to create an even surface for the next production step or to eliminate loose threads at the edge of the fabric. In particular, at the digital printing process loose weft ends can create a worst-case scenario, where the digital printing head can rip the weft out of the textile web, causing severe damage on the web and on the printing head itself. A simple principle applies here: A reliable detection is essential and the less cutting waste, the more profit.
In other words: every millimeter counts, as the amount of fabric accumulated over the course of a year can easily add up to hundreds of tons of fabric. With its AI-based ELWARP SI 2001 sensor, Erhardt+Leimer offers a high-precision sensor for optical detection of the selvedge thread in a web, regardless of the length of protruding weft threads. Instead of a wild guess by deducting a constant offset from the end of the longest weft thread, the smart AI based principle is focusing constantly directly on the selvedge thread. More than that an algorithm supports the AI whenever the thread is not visible anymore and adds on the factor of probability whenever necessary. This allows for more precise cutting, saving real money in the process.
ELCLEAN – the answers to many problems
We see the dust and the loose fibers everywhere in the textile production. However, do we also have in mind the damage that they may cause? They are blocking sensors and motors. Together with grease, they form a concrete-like hazard to all the moving parts of your machines. They are the nightmare of every printing division as they leave fatal reserves. Moreover, that is just the visible part of the damage.
The invisible part is happening in all the wet finishing processes as well as during the wastewater treatment. Here, the fluff and the dust are causing real trouble, as it is not visible to the human eye, what they are up to.
During the bleaching, mercerizing or also during the dyeing process, they are consuming as much chemicals, dyestuff, water and energy as the “real” fabric. And finally, at the water treatment, they are responsible for an increased BOD value.
ELCLEAN: the answer to uncontrolled water, chemical and production cost
Erhardt+Leimer (E+L) provides more than 100 years of experience to the performance of the textile value-added chain. Looking into the details of the different steps is part of our DNA. Fact is: The sooner we eliminate fluff and dust from the production cycle, the more money can be saved. This is why the installation of the ELCLEAN system is best right before any wet finishing process.
The innovative system will separate fluff and fibers right before they can cause damage to the infrastructure or the cost of production. It consists of a sophisticated air blade system that is able to remove the contamination and collect it in a dedicated bag by means of a cyclone separator. No more damage of prints, machines or uncontrolled wastage of chemicals and energy.