The world’s first Crosslapper machine was produced in 1929. From the original technology that started the Industrial Age, Textile Machine manufacturing has always been dependent upon innovation to improve productivity and market position. When a leading manufacturer needed to make a radical update to their Crosslapper Technology they contacted Quin Systems to produce the most technically advanced solution.

Crosslapping is a technique of layering thin layers of fibre to produce a density of thickness required for non-woven textile products such as carpets, floor-tiles, bedding, shoe linings, automobile interior mouldings and other fabrics. There is a need for high repeatability, continuous high quality and flexible batch handling and changeovers.

The traditional machine was complex and used mainly mechanical systems to synchronise and control the machine’s motion; this made machine setting a long task and therefore running small batches inefficient. Controlling density across the width of the web was also difficult, particularly at the ends – providing a quality issue, and unacceptable trimming losses. It was clear that the mechanical solution was unsustainable in delivering a machine that would be productive in today’s business environment.

…a clean piece of paper
Once a new solution was sought then a list of requirements could be made. This list was finalised as doubling the speed of the original machine, accurate and uniform cross-sectional density across the web – with no waste, and rapid changeover between batches without stopping and with no need to change any parts.

…working the problem
The combination of the builder’s engineering team and Quin’s Motion Control Consultants had the right expertise to deliver a solution. This was undertaken using computer software tools to analyse the machine’s motion, together with Quin’s Motion Generator software. Each motion element was then applied to a specialist mechanical design tool – the Quin System’s Camlinks model. This produced validated motions and correct torque and speed calculations for motor selection. The detailed analysis allowed Quin to prove that the project aims were achievable. The next stage was to jointly develop the machine and the machine’s motion control system.

Delivering the benefits…
The resulting machine fully achieved its design specification. The speed being increased from 60 to 150 metres per minute, and changeover between batches now takes only 2 minutes.

The redesigned machine is mechanically and electrically built as modules, this has lowered build costs and the design quality has improved reliability.

The machine can be remotely linked to the machine builder’s electronic service centre, allowing immediate specialist engineering support and customer service, globally.

Quin’s PTS (programmable Transmission System) has eliminated many mechanical devices such as multiple chains and sprockets, this allows for the use of endless conveyors. These allow the enduser to make these up completely automatically as opposed to the laborious assembly of rolls of conveyor material with heat and glue – not a desirable activity in a textile environment.

“The machine produces excellent product – consistently, and we are very happy with its performance” … David Oldham, Production Manager, Highams.

Competitive collaboration…
The joint development between the machine builder and Quin Systems has succeeded in a difficult time for textile machinery builders. The radical and wholesale adoption of electronic motion control has delivered many benefits both to the builder and to the textile manufacturer. The combined expertise of the two companies overcame many problems and produced a machine that is as revolutionary today as its predecessor was in 1929.