Embroidery in record time
Baumüller supplies a highly dynamic drive system for the MVD75 large embroidery machine from LÄSSER AG
How can a wide variety of textiles be finished in record time? With large-scale embroidery machines from LÄSSER AG. The newly developed MVD75 high-performance shuttle embroidery machine enables the finishing of textiles such as tulle, cotton, lurex, paper, and much more. With highly dynamic drives and a robust and sophisticated design, the machine combines high production speed with unmatched embroidery quality.
Fabrics with embroidery patterns are extremely versatile. They can be used to make clothing, seat cushions, curtains, borders, and more. The machine's task is to apply high-quality embroidery patterns and appliqués in record time. “Every material behaves differently. That's the biggest challenge,” explains Reto Spirig, Head of Control Technology at LÄSSER AG.
Comprehensive process knowledge for optimal results
LÄSSER AG, based in Diepoldsau in the canton of St. Gallen in Switzerland, is the world's leading manufacturer of large embroidery machines.
In 1954, LÄSSER founded a mechanical workshop in the center of Diepoldsau. This workshop manufactured parts and equipment for existing embroidery machines and carried out repairs, electrification, and overhauls of embroidery machines. In the 1970s, the first embroidery machine was developed and built. It could sew approximately 180 stitches per minute, ran on electric controls and stepper motors. In 1982, development began on the first computer-controlled LÄSSER embroidery machine, which was successfully put into operation the following year in neighboring Lustenau (AT).
The high-performance shuttle embroidery machine MVD75 is up to 30 meters long and impresses with a high speed of up to 700 stitches per minute.
Today's machines can sew over 700 stitches per minute. With around 200 employees, LÄSSER AG produces 80 to 100 embroidery machines per year with a length of 5 to 30 meters. This allows for patterns with a variance of a few to almost an infinite number of stitches.
End users have very high demands: “Baumüller offers excellent reliability. This is extremely important, as the machine has to run 24/7,” explains Reto Spirig. In addition to reliability, the speed and service life of the large embroidery machine also play a major role. "Not every motor manufacturer can deliver the dynamics we need. In Baumüller, we have found a partner with whom we have been working for more than 35 years. We drive each other forward to promote innovation and offer modern solutions."
LÄSSER relies on an efficient drive system from Baumüller. The solution consists of the dynamic DSD2 servo motor series and the b maXX 5300 series system.
Intelligent control system
At the heart of the machine is the intelligent LPilot control system developed in-house by LÄSSER. The software enables higher speeds with even better embroidery quality. All machine functions, such as optimized drilling movement and automatic tensioning of the frame, are integrated into it. The machine is controlled quickly and easily via the touchscreen. The machine software offers the user a wide range of settings and flexibility.
The end user designs an embroidery pattern and uses a punching machine, similar to a CAD system, to generate the embroidery program that is processed by the machine. “Anything your imagination can come up with is possible with our embroidery machines,” explains Reto Spirig.
Servo motors for increased dynamics
The highly dynamic servo motors of the DSD2 series from Baumüller are used, which were designed for the highest demands on acceleration capacity and the best start-stop qualities. These have an excellent torque-inertia ratio. This ensures maximum dynamics, i.e., fast and precise embroidery production. The movements of the individual drives must be synchronized with each other with high precision in order to achieve accurate embroidery results. The DSD2 drives have very good running characteristics and, in combination with Baumüller's b maXX servo controllers, enable high position and speed accuracy. The components work together perfectly and are very energy-efficient, as they share energy in the DC link network.
The dynamic DSD2 servo motor series enables high production speeds and unmatched embroidery quality. 
The compact servo controllers of the b maXX 5300 modular system reduce wiring effort thanks to integrated safety and FSoE functionalities.
The b maXX 5300 series system with integrated safety functionality controls the main and auxiliary drives with high precision. If necessary, the STO safety function is triggered with a controlled time delay in order to shut down the drives quickly but in a controlled manner. Once the parameterized time has elapsed, the drives are switched to zero torque. The additional DC link capacitor unit stores energy during the braking process of the servo motors. The embroidery machine uses this energy for renewed acceleration, thus saving energy. Baumüller supported LÄSSER with the drive dimensioning and initial commissioning of the large embroidery machine. Further drive optimizations are currently being worked on using the ProSimulation simulation tool.
Baumüller has customized the DSD2 dynamic servomotor to better handle the high radial forces of the two main shafts.
"We value a cooperative relationship and a very comprehensive range of functions, such as safety technology and much more. But also on flexibility when something needs to be optimized," says control expert Reto Spirig, praising the collaboration with Baumüller. In order to better handle the high radial forces of the main shafts, Baumüller made a customer-specific adaptation and, together with LÄSSER, developed a special flange bearing shield including special bearings. The result is a solution of impressive precision and harmony that offers high reliability in 24/7 operation. This has led to even smoother running characteristics and significantly reduced wear. Excellent embroidery quality—even at high speeds—is achieved through high-precision synchronization of processes with drastically reduced stresses and torsions in the system.
Smart teamwork
Reto Spirig, Head of Control Technology, LÄSSER AG:
“We work very closely with Baumüller as partners. This partnership means that we actively seek solutions, benefit from short communication channels, can quickly exchange information with Baumüller's experts, and know that the components will be available for a long time. Embroidery machines have a very long service life, which means that even when a machine is ten years old, it is still considered new. Baumüller products cover a life cycle of more than 20 years.”
LÄSSER AG develops and manufactures exclusively at its production site in Diepoldsau, Switzerland. The embroidery machine is pre-assembled and then finally assembled and commissioned at the end user's premises.
Conclusion
The high-performance shuttle embroidery machine MVD75 is dynamic, fast, and precise. It can be used to finish a wide variety of materials in record time. Thanks to the excellent partnership between LÄSSER AG and Baumüller, a compact drive system has been developed that benefits from high dynamics, precise control, and a space-saving drive concept. For more than 35 years, new innovative embroidery machines with state-of-the-art solutions have been developed. Thanks to flexible and customer-specific adaptations and further developments of the drive system, the MVD75 offers high production speed and unmatched embroidery quality.
