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Case Studies - Custom Lighting

Computer Numerical Control (CNC) Embroidery Equipment

The largest OEM manufacturer of computerized multi-head embroidery equipment needed to improve sewing quality and speed up rethreading needles

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Situation - The largest OEM manufacturer of computerized multi-head embroidery equipment needed to improve sewing quality and speed up rethreading needles when threads break. A thread break �auto-stopped� the machine and operators could not see the needle holes well enough to efficiently do the re-threading. They also had difficulty seeing the sewing work surface to verify garment quality. This was a major quality control and operations problem forthis manufacturer�s customers. The manufacturer asked Crownlite for a solution to help his customers and as a competitive advantage for added sales.

Challenge - There where several models of machines ranging from 1-8 sewing heads. The lighting system had to fit new machines and be retrofitable onto all machines already in the field. The task area between sewing head needles and the product being sewn is a gap of less than one inch. The sewing area is in constant motion. The machine operator�s body cast a dark shadow onto the task area when he/she rethreaded any of the needles. The manufacturer tried several off the shelf light fixtures and ended up making more shadows. The system had to be made to metric dimensions.

Crownlite�s Process - Crownlite inspected several live installations of equipment and reviewed detailed CAD drawings of each machine configuration. A thorough analysis of each machine was done to identify obstructions, avoid delicate internal electronic components, determine correct sizes, and position mounting locations. We tdeveloped a unique lighting system concept around a custom specular reflector that would put as much light as possible right on the work area. 3D CAD computer mockups were done of each machine with it�s new lighting system.

Solution - Crownlite designed a custom lighting fixture and reflector system that integrated directly into the machine. The system directed as much lght as possible onto the task area without creating shadows. The new system was easily scalable to work with each machine in the customers� line � new and already in the field. From this basic design concept, Crownlite built an entire family of fixtures.

Result - Originally, the machine manufacturer offered the lighting fixture as an added-value upgrade for older machines, and to gain a sales advantage for new sales. Over a 3 year period several thousand fixtures where sold. The lighting system is now standard on all new machines.

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