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Engineered sewing station for documented airbag tearing seams


The continuously improved protection of car passengers realized by the introduction of airbags makes increased demands on the seams of the automotive interior.
In case of an accident the airbags integrated in seat covers, door panels or car fittings have to break through in an exactly defined seam section. This safety-relevant seam must be strong enough to resist the stress under normal conditions and at the same time it must guarantee the unrestricted, accurate exit of the airbag.
Dürkopp Adler has developed the new engineered sewing station 550-867 to realize these airbag tearing seams in a professional way.
The overall concept is oriented on process reliability as well as on the monitoring and documentation of the given sewing parameters and sewing processes.

More safety:
• Inspection of the workpieces and sewing thread lots
• Permanent monitoring of the sewing parameters
• Permanent control of the sewing processes
• High process reliability through to identification of skip stitches and false sewing (function module SSD) 
• Error indication with subsequent sewing stop
• Constant documentation of all production data
• Constant sewing results in different materials
• High seam quality due to monitoring of the thread tension
• Trouble-free material feed owing to the powerful and effective feeding system
• Easy handling of the service-friendly hardware and software components
• Computer-controlled sewing processes
• Automatic adaptation of the sewing parameters
• Unproblematic processing of all customary cover materials owing to the proven lockstitch sewing technology of M-TYPE cl. 867
• Easier adaptation in case of style change due to automatic adjustment elements and easy seam programming

Basic equipment of the engineered sewing station 550-867:
• Sewing head based on M-TYPE 867-190445:
Single-needle lockstitch machine with bottom feed, needle feed and alternating foot top feed, electromagnetic short cut thread trimmer (remaining thread length approx. 5 mm), electromagnetic thread clamp, automatic seam backtacking, electropneumatic sewing foot lift and quick stroke adjustment,
XXL hook (bobbin diameter 32 mm), integrated LED sewing lamp, maintenance indicator
• Stepping motor for automatic stitch length adjustment and seam backtacking according to the given sewing parameters of the different seam sections
• Multi-position cylinder for automatic stroke adjustment according to the given sewing parameters of the different seam sections
• Thread tension sensor for permanent monitoring of the needle thread tension
• Motor-driven bobbin winder with winding assistant and plausibility check for registration and data link of bobbin number and sewing thread lot
• Bobbins with modified inner diameter and numerical bobbin labelling (optionally with barcode information) for bobbin identification
• Identification of bobbin thread and needle thread by means of manual barcode registration
• Plausibility check in case of bobbin change by hook cover control
• Photoelectrical monitor for the remaining bobbin thread RFW 20-7
• Power supply unit (UPS) for uninterrupted power supply
• Identification of operators with classified access permission
• Handscanner for registration of the barcodes for entry, sewing thread and access permission
• Collection, control and storage of data by network-capable 15“ Touch-Panel PC
• User-friendly software
• Rotatable thread stand for 6 thread cones with monitoring of cone change by means of proximity switch
• Machine stand on rollers, height adjustable by motor for standing and sitting operation
• Administrator set consisting of a plastic case with the following contents: PC-mouse, keyboard, USB-hub, admin access dongle, memory stick for EFKA parameter setting, memory stick for PC recovery files, key set for padlocks

Required equipment of the engineered sewing station 550-867:
• Optionally with rectangular table top (1600 x 920 mm) or L-shape table top (1600 x 920 x 1300 mm)
• Sewing equipment optionally for 6 mm or 9 mm stitch length
• Optionally with mechanically adjustable thread tension (MTT with thread tension sensor and locking element) or with electronically regulated thread tension (ETT with thread tension sensor) for programmable needle thread tensions in the different seam sections
• Optionally with special edge guide with integrated glass fibre optics for the exact recognition of the side airbag seam section (notch detection) or sensory edge monitoring device (EMD) with integrated notch detection (on request)
• Barcode printer for end label (optionally standard printer or installation of a customerspecific printer on request)

Optional equipment 550-867:
0867 590724 Barcode scanner with holder for endlabel recognition
0867 590764 Barcode scanner with holder for endlabel recognition (2D-Matrix)
0867 590904 Scanner (2 x) with holder for scanning the barcodes of the bobbin thread and needle thread cones
0867 590884 Scanner (2 x) with holder for scanning the barcodes of the bobbin thread and needle thread cones (2D-Matrix)
0867 590924 Scanner (2 x) with holder for the identification of the bobbin barcode (hook and bobbin winder)
0867 590014 Needle cooler, top (NK 20-1)
0867 590054 Needle Cooler, bottom (NK 20-5)
9800 330010 Control panel EFKA V820
9999 000020 Z User-specific software modification (on request)
9040 000030 Thread tension measurement device
0867 590974 Holder for label rolls

0867 591414 Fingerprint sensor

March 2, 2017: Zebra Technologies Corporation Recalls Power Supply Units for Thermal Printers Due to Potentially Overheating or Fire Hazard: Relevant for Dürkopp Adler Industrial Sewing Machines Class 550-867. More information

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