Delta Motion Control Provides an Efficient Industrial Sewing Machine Solution for the Garment Industry

The garment industry is a traditional industry with a long history and well-developed industrial structure. However, to cater customers' emerging ordering habits and higher requirements of quality and efficiency, the production mode of the garment industry has shifted from standard mass production to customized production with small quantities and wide varieties. Frequent changeovers, complicated production processes, and high labor costs have increased management costs, so garment manufacturers are starting to implement automated equipment and are seeking to upgrade production solutions. Replacing manual labor with automated machinery does not only shorten production time and save direct costs, but also achieves flexible manufacturing and maintains consistent and meticulous quality for finished garments.

To fulfill the requirements of automated sewing, Delta has provided a European garment manufacturer with an efficient industrial sewing machine for automatic trouser pocket setting. This solution uses the Delta Network Type Advanced Slim PLC DVP-SE Series as master control, connecting the Delta AC Servo Drive & Motor ASDA-A2 Series via CANopen communication. The ASDA-A2 servo drives control two axes of the ECMA series servo motors for sewing operations. Via the Delta 4.3-inch Widescreen HMI DOP-B Series, users can set up parameters and monitor the real-time sewing process to ensure successful production.

In actual application, Delta's industrial sewing machine solution brings the following benefits to our customers:

• High-speed control and communication: This solution adopts the Delta Network Type Advanced Slim PLC DVP-SE Series as a master control. The DVP-SE Series delivers up to 0.64μs high execution speed with built-in Mini USB, Ethernet and two sets of RS-485 ports, making it the most complete network communication controller in the market. The built-in IP Filter functions as a firewall for first line protection against malware and network threats. The DVP-SE Series supports the DVP-S Series' left-side and right-side modules for various extensions. In this solution, it controls AC servo drives with the high-speed extension module CANopen Master DVP-COPM via CANopen communication to achieve highly efficient sewing machine operations.

• Real-time setting and monitoring: Delta's 4.3-inch Widescreen HMI DOP-B Series is integrated in the industrial sewing machine. The DOP-B Series' full 65,536-color LED screen provides a realistic image display. Users can set up sewing parameters and monitor the production and operation status of the machine easily with the HMI. The DOP-B Series is equipped with an audio output interface. In case of errors, an alarm alerts users via an audio message in real-time to prevent delays in operation and sewing efficiency.

• Stable and accurate solution: Delta's industrial sewing machine solution adopts the AC Servo Drive ASDA-A2 Series to control two axes of ECMA servo motors for sewing operations. The full-closed loop function reduces the effects of backlash and vibration from the machine and ensures the accuracy of positioning. The ECMA servo motors feature incremental encoders with 20-bit resolution that can eliminate unstable commands at low speed and enhance accuracy. They also support an absolute 17-bit encoder and are able to maintain motor position when the power is off, fulfilling customer's expectations for accurate and stable pocket setting.

Delta's industrial sewing machine solution achieves customer's requirements for efficient and accurate manufacturing. Delta continues to offer comprehensive solutions to meet our customers' diverse requirements and ensure an outstanding future together.