Development Trend of Computer Embroidery Technology

Customs statistics show that from January to August 2010, China imported a total of 0.05 million units of embroidery machines, an increase of 59% compared with the same period of last year. The total amount of imports reached 15.0210 million US dollars, an increase of 112.39% year-on-year. Under such circumstances, how should domestic computerized embroidery machine manufacturers respond? What will be the technological development of computer embroidery in the future?

Since the outbreak of the global financial crisis, the computerized embroidery machine industry has undergone several rapid changes: “suddenly” and “suddenly down”. The Indian market has changed and the domestic textile and clothing industry has undergone transformation and upgrading to domestic and foreign computerized embroidery machine manufacturers. Performance has two distinctly different effects. According to customs statistics, from January to August 2010, China exported a total of 23,300 embroidery machines, a decrease of 32.32% year-on-year, and a total of 18,934.03 million US dollars of export value, a year-on-year decrease of 30.01%. In the computer embroidery machine industry dominated by foreign trade, the Indian market shivered with a bit of trouble. The overall weakness of the domestic computerized embroidery machine industry in 2010 was due in large part to the shrinking Indian market. At the same time, sales of imported embroidery machines are in full swing in China. Customs statistics show that from January to August 2010, China imported a total of 0.05 million units of embroidery machines, an increase of 59% compared with the same period of last year. The total amount of imports reached 15.0210 million US dollars, an increase of 112.39% year-on-year. Under such circumstances, how should domestic computerized embroidery machine manufacturers respond? What will be the technological development of computer embroidery in the future? The related issues are discussed below.

Trend 1: High-efficiency computerized embroidery machines are developing in an efficient and fully automated manner. In recent years, with the further intensification of labor shortage, both embroidery and garment companies have imposed higher requirements on the production efficiency of computerized embroidery machines. As a result, all manufacturers are constantly refreshing the speed record of the computerized embroidery machine. From 1 000 revolutions per minute to 1 300 revolutions per minute, and to 1 500 revolutions per minute, the spindle speed of the computerized embroidery machine also leapt to a new level. . For example, South Korea Sunstar, which pioneered the “highest speed in the industry” slogan, has achieved a maximum speed of 1,300 rpm per SWF/DM series ultra-large high-speed multi-head embroidery machine (56 heads). 1 500 revolutions per minute. The TNBK high-speed computerized embroidery machine's embroidery speed of the main North Bird has also reached 1 200 rpm and the noise of the whole machine is less than 85 dB.

In fact, we say that the speed of a machine is 1500 rpm, not that this machine has been 1500 rpm in the embroidery process, the electronic control system will adjust the speed of embroidery according to the stitch length, and the needle length is longer. At this time, the spindle speed will drop to a relatively low level to meet the timing requirements of the moving frame. Therefore, the length of the switch needle determines the key to slow down. In view of this situation, Beijing Xing Dahao proposed the concept of full-servo high-efficiency machine with 8mm switching needle length and no deceleration. By reducing the number of needles to be switched, the embroidery machine always works at a high speed of 850 rpm and reduces The mechanical loss reduces the breakage rate, so as to achieve the purpose of high efficiency and practicality. At present, this technology has been used by some manufacturers. The high rotational speed brings a lot of challenges to mechanical structures and materials, such as noise, vibration and spiroidal intensity, high temperature resistance and so on. If the manufacturer does not upgrade and improve the key components during the design and installation process, it will directly affect the performance of the entire machine or the embroidery effect cannot be guaranteed. For example, the life of the machine will be greatly shortened, and the noise and vibration will be large and broken. High line rate problems.

"Super multihead" is also one of the ways to develop the computerized embroidery machine with high efficiency. In 2009 CISMA, Shenzhen Yifeng Embroidery Machine Factory exhibited a 86-head multi-headed computerized embroidery machine. Zhejiang Shengming Electromechanical Manufacturing Co., Ltd. exhibited a GG758-P475 type 75-head multi-headed computerized embroidery machine. Leading companies in computer embroidery machines such as Tajima, BEHRINGER, and Sunstar have also launched 56 super multihead computer embroidery machines. In general, an ultra-multi head embroidery machine refers to an embroidery machine with more than 40 heads. This model mainly replaces traditional shuttle embroidery machines for the production of large-area home textiles such as curtains and bed sheets. Compared with the traditional shuttle embroidery machine, the ultra-long multi-head computerized embroidery machine is small in size, requires relatively less investment, makes embroidery more convenient, and has higher speed and richer colors. Taking the Tajima TFGN-650 series of 50 multi-head multi-headed embroidery machines as an example, the area of ​​its embroidery reaches 162.4 square meters, which is 6 times the head distance of the 27.8 square millimeters of the shuttle embroidery machine. Compared to the shuttle embroidery machine, there are only 3 color restrictions, TFGN has 6 colors to choose from. In addition, each head can be equipped with a high-speed bead embroidery device, making production options more diversified.
Trend 2: four-in-one Because the traditional special embroidery machine control system (dish tape embroidery, chain embroidery) mostly uses centralized control, the design of four-in-one embroidery machine requires higher mechanical assembly technology, so the current domestic multi-function Embroidery machines are mainly based on three-in-one models. However, Japanese companies such as Tajima and BEHRINGER have achieved a single embroidery machine with a combination of four types of basic embroidery methods: lock embroidery, sequin embroidery, dribbling embroidery, and chain embroidery. On the German IMB in 2009, Japanese Tajima, BEHRINGER, South Korea Sunstar, and German ZSK all exhibited flat embroidery, towel embroidery, dribbling embroidery, and gold embroidery four-in-one hybrid embroidery models. The existing embroidery machines will be displayed. Most of the features are combined on one machine. Among them, Tajima exhibited a chain-wound embroidery instead of a tape-and-tape embroider, and Rixing exhibited a simple tape-and-tape embroidering instead of a dribbling embroidery. This shows that although the independent tape leader can achieve a variety of dribbling, winding, zigzag, rope embroidery and Other complex embroidery methods, but the number of users who require such a comprehensive embroidery method is still a small one, and the function achieved through the simple dribbling embroidery can satisfy the large The needs of some users, while significantly reducing the cost, the main function of the market in the future is the combination of flat embroidery, sequin embroidered, towel embroidered and simple tape embroidered functions.

In response to this, during CISMA2009, Hing Dahao launched the CX8 4-in-1 computerized embroidery machine control system chain embroidery function system. The system introduced the DCS control method into the embroidery machine control system, broke the mechanical assembly bottleneck of the multifunctional embroidery machine, and made it possible to combine multiple embroidery methods with a single machine. The system center controller also has four basic embroidery control modules: lock-type embroidery control system, sequin embroidery control system, pan-belt embroidery control system, and chain embroidery control system. The four embroidery systems can be automatically switched between each other, which saves the stitching time in the combined pattern embroidery and improves work efficiency, and ensures the accuracy of the pattern stitching (which can reach ± ​​0.1 mm, which fully meets the aesthetic needs of embroidery). It has good maintainability, independent head control system has high reliability and is easy to maintain. Individual head system failure does not affect the normal operation of the whole machine. Embroidery efficiency has also been improved, its special embroidery head adopts independent control mode, which reduces the load of a single motor, thus enabling high-speed special embroidery and improving work efficiency. In addition, its single head consumes only 30 watts, a 66% savings over conventional models.

Combining this leading control technology, Zhejiang Xinsheng Sewing Equipment Co., Ltd. recently successfully developed a new generation of computerized embroidery machines. This computerized embroidery machine gathers five functions such as sequin embroidery, tape embroidery, and towel embroidery, which not only greatly increase the embroidery efficiency, but also embroider more fashionable patterns. In the past two years, Xinsheng Company continued to maintain double-digit growth in sales revenue thanks to its “four-in-one” and “five-in-one” embroidery machines, which have yielded huge profits. At the 2010 Dongguan show, the new TCMX towel embroidery machine displayed at Tajima uses a pair of machine head operation modes on a single machine. It can also be equipped with two heads for towel embroidery and flat embroidery to realize different models. The combination of embroidery can not only greatly increase production efficiency, but also realize ever-changing embroidery design.

Trend 3: Combination of Embroidery and Laser Technology Laser technology has been applied to embroidery machines for many years, but it has not become the mainstream of market sales. At present, there are mainly three kinds of embroidery machines that use laser technology: one is an embroidery laser machine, and the same control system is used for laser control and embroidery machine control, such as the Tajima TFGN-1202, which is characterized in that each head is cut at the same time but the laser power is low. Low cost; one is the laser control system is independent of the embroidery control system, mostly bridge type laser engraving cutting machine, the characteristics of such machines are not limited by the number of embroidery heads, sharing a laser system, mostly galvanometer-type high speed Laser, through the dynamic focusing system can achieve high-speed precision large-scale cutting, by adjusting the size of the laser spot can achieve laser full cut and half-cut different effects; the third is the laser is applied to the positioning system embroidery machine, such as Braun A four-point laser positioner developed in cooperation with an Italian company.

At present, there are more embroidery machines in the first two combinations on the market. The processing of materials such as fabrics and leathers often requires the laser cutting machine and the peaceful embroidery machine to handle separately. This not only reduces the production efficiency, but also affects the processing quality. It is also easy to introduce errors due to incompatible formats. The combination of embroidery laser technology can achieve the functions of cutting, engraving, spray printing, etc. on the basis of flat embroidery. At the same time, it can take into consideration the free combination of gold embroidery and dribbling embroidery, and can be applied to patchwork embroidery Three-dimensional embroidery and other embroidery fields. Compared with the two-in-one model that controls laser and flat embroidery separately, the advantages of the embroidery laser integrated machine in terms of ease of operation, pattern making, cutting efficiency, and switching accuracy are even more obvious.

BEHRINGER applies laser technology mainly to positioning. The traditional positioning has the following disadvantages: Each time the patch is replaced, it must be framed, wasting time and materials; the printed fabric is easy to be damaged and broken, resulting in scrap; in the course of patching, film taking and embroidery, such as broken lines and broken needles. Or reverse the needle, easy to hurt the hand; if the push pin moves, fall off, it is easy to cause damage to the mechanical parts. The use of four-point laser positioning not only saves time and effort but also ensures accuracy and material savings.
Reality and Gap In a meeting, the person in charge of an embroidery machine company said: “The biggest confusion we have now is that we have no direction. Foreign-funded enterprises have had little technological upgrading in recent years. We have all kinds of models that we have.” Most of the domestic computerized embroidery machines only learn like, especially in terms of mechanical properties, there is still much room for improvement.

Let's take a look at the several patents that Tajima has obtained. Tajima developed a special rotary hook for the TFGN series of multi-head embroidery machines. Even at high speeds, the rotary hook can achieve stable and even results. The "Rotary Light Induction Breakage Induction" patent quickly detects an upper or lower wire breakage even at high speeds. The patent of “adapting to high-speed thread tension” has enabled the line tension and needle step to be more stable and smooth due to the use of a spring-type midline (patent pending) and lock-on mechanism (patented) under high-speed operation. The M-axis independent control system of the Tajima TLMX series of circular seam embroidery, tape, and reel embroidery machines can be calibrated on a machine-by-tool basis. The serrated embroidery auxiliary device (patent pending) enables the swing distance to be controlled at the operating panel. Adjusting from 6mm to 16mm helps prevent collisions with needles when embroidering thicker materials. From these patents, it can be seen that Tajima has been making continuous efforts to continuously improve the performance of machines, which is also the main reason why it firmly holds the top spot in the high-end market. However, few domestic products can enter enterprises that are specialized for foreign brands.

In terms of attachment development, the performance of domestic embroidery machine companies is also not satisfactory. This is mainly related to the orientation of companies and R&D ideas - they are busy with price wars and do not pay attention to user needs. While foreign companies such as Tajima and Sunstar, through active full-service, form good interaction with users and grasp first-hand market information, which lays a solid foundation for their product development, improvement, and increase of product added value. From the following parts of Tajima, we can see the purpose of “all-round embroidery service” for customers. "Automatic replacement of the bottom line device" replaces the bottom line with a machine instead of a human hand. Each machine head can carry three bobbins loaded with a bottom line at the same time, which is quick and easy, and can greatly reduce downtime. "Automated Whole Horseshoe Embroidery", full-length horseshoe embroidering refers to putting the whole piece of cloth on the embroidery machine for continuous embroidery. This device can improve the quality and perfection of the whole horse. "Automatic refueling device", this system can regularly refuel the needle and rotary hook parts to reduce the workload of operators and effectively increase productivity.

When many domestic embroidery machine companies are still fighting for foreign orders, “Taipei people”, Tajima, Japan Star and other companies also stepped up to dig deeper into the Chinese market. If domestic companies do not adjust their strategies in time, identify technological development trends, and keep steady, they will easily lose themselves in the ups and downs of the market. (wy)