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Segment Brochures "Airbag"

Segment Brochures "Airbag"
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Segment Brochures "Airbag"

Product catalog summary
Overview: The document discusses KSL's advanced sewing solutions for airbag manufacturing, highlighting their focus on performance, quality, and process reliability. KSL is a leader in the textile and leather processing industry, offering customized solutions for automotive manufacturers and suppliers.
1. Airbag Sewing Solutions: KSL provides a variety of CNC sewing units tailored for different airbag types, such as headbags, curtain airbags, and driver/passenger airbags. These units feature rotating and stationary sewing heads and silicone application capabilities.
2. CNC Sewing Units: Detailed descriptions of CNC sewing units like KL 110, KL 311, KL 310, and KL 300 are provided, each designed for specific airbag applications. Key features include sewing area dimensions, stitch types, sewing speed, and options like thread tension adjustment and automatic template detection.
3. Manual Sewing Machines and Robotic Technology: The document also covers manual sewing machines from PFAFF INDUSTRIAL and Dürkopp Adler, along with robotic technology used in the manufacturing process.
4. Laboratory and Quality Control: Emphasizes the importance of simulations, case studies, and integrated quality control systems to ensure safety and reliability in the sewing process.
5. Features and Options: Sewing units include features like vertical hook systems, electromagnetic thread trimmers, touch screen operator panels, and options for integrating barcode scanners and safety monitoring systems.
Conclusion: KSL's innovative solutions meet the specific needs of the automotive industry, ensuring high-quality, reliable airbag production with advanced technology and customization options.
Specifications and Features:
  • CNC Sewing Units: Designed for servo-motorically controlled sewing of safety, functional, and decorative seams with modular machine design and selectable sewing heads.
  • Sewing Area: Ranges from 300 x 300 mm to 3,000 x 1,000 mm for various airbag sizes.
  • Stitch Types: Includes 1-needle double lockstitch, 1- or 2-needle chainstitch, and 3-needle double chainstitch.
  • Advanced Features: Automatic template detection, touch screen operator panels, pneumatic thread trimmers, and programmable thread tension.
  • Customization Options: Feeding tables, alternative thread trimming devices, and integration of safety monitoring systems.
Applications:
  • Designed for all airbag manufacturing areas, including inflator and deflator openings, sewing around flange drillings, and attaching reinforcement parts.
  • Specific units tailored for closing round driver and passenger airbags, as well as side and knee airbags.
Additional Units:
  • CNC Silicone Unit: For applying silicone on curtain airbags with servo-motorically adjustable height and vacuum systems.
  • Outer Seam Sewing Unit: For closing outer seams on round airbags with high-speed operation and automatic unloading systems.
  • CNC Polar Axis Sewing Unit: Designed for sewing airbags with small radii, featuring a 360° rotating sewing head.
Options and Customization:
  • Units can be equipped with programmable presser foot height, additional thread tension adjustments, and integration of RFID sensors and barcode scanners.
  • Customizable features enhance the versatility of the sewing units to meet specific customer requirements.
Electromagnetic Thread Clamping Device: Ensures neat seam beginnings with performance recording via a piece counter, supporting up to 200 seam programs with a maximum of 16,000 stitches and 20 different sewing sequences.
Special Workplace for Airbag Seam Sewing: Includes constant documentation and monitoring of production data, inspection of workpieces and sewing thread lots, and high process reliability through skip stitch and false sewing identification.
3D Robotic Systems: Combines sewing competence with handling and tooling expertise for robot-supported production of decorative seams, ensuring reproducible constant stitch length and minimal operator intervention.
KSL Laboratory: Established in 2015, it serves as a center of excellence for developing customer-oriented solutions, conducting feasibility studies, realizing prototypes, and designing special sewing heads.
Contact Information: PFAFF Industriesysteme und Maschinen GmbH, Branch Office KSL, Bertha-Benz-Straße 4, 64625 Bensheim, Germany. Phone: +49 (0) 6251 9620-0, Email: [email protected].
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Catalog excerpts

Segment Brochures "Airbag"-1

Sewing solutions for processing Airbags Nählösungen für die Airbagfertigung 1

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Segment Brochures "Airbag"-2

When manufacturing airbags (functional and safety-relevant seams), the manufacturers (car manufacturers and automotive suppliers) count on the performance, quality and process reliability of KSL airbag solutions. The customer list at KSL reads like a „Who is Who“ of the automotive industry featuring prestigious brands from all continents. The manufacturers demand solutions with customized individual and process reliable controlled applications that ensure maximum reproduction of their airbags. With KSL, the customer‘s individual requirements are already recorded in the project phase and consistently...

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Segment Brochures "Airbag"-3

CNC Headbag sewing unit with turning head Headbag-, curtain-, window airbags all seams, with rotating sewing head, preferably for 2-needle applications CNC Sewing unit with turning head all seams, with rotating sewing head, preferably for 2-needle applications CNC sewing unit with stationary sewing head Headbag-, curtain-, window airbags all seams, with stationary sewing head for 1-needle applications CNC Sewing unit with stationary sewing head Driver-, passenger airbags inflator- and deflator openings, reinforcement parts and tether tapes Headbag-, curtain-, window airbags application of the...

 Open the catalog to page 3
Segment Brochures "Airbag"-5

Arten von Airbags / Types of airbags Driver Airbags Passenger Airbags Side Airbags Curtain Airbags Knee Airbags Thorax Airbags

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Segment Brochures "Airbag"-7

• Headbags, Curtain-Airbags, Window-Airbags • Headbags, Curtain-Airbags, Window-Airbags CNC-Nähanlage mit 360° drehbarem Drehkopf für servo-motorisch gesteuertes Nähen frei-programmierbarer Sicherheits-, Funktions- und dekorativer Nähte. Höchste Nahtqualität durch tangentiale Ausrichtung des Nähkopfes in beliebiger Nährichtung (modularer Maschinenaufbau) Sewing area: 1,600 x 800 mm to 3,500 x 800 mm Stitch type: 1- or 2-needle double lockstitch, or 1- or 2-needle chainstitch (option) Excellent sewing properties due to vertical hook system Stitch length max. 12 mm / Sewing speed: max. 2,800 stitches/min....

 Open the catalog to page 7
Segment Brochures "Airbag"-9

CNC-Nähanlage mit 360° drehbarem Drehkopf für servo-motorisch gesteuertes Nähen frei-programmierbarer Sicherheits-, Funktions- und dekorativer Nähte. Höchste Nahtqualität durch tangentiale Ausrichtung des Nähkopfes in beliebiger Nährichtung (modularer Maschinenaufbau) CNC sewing unit with 360° rotating sewing head for servo-motorically controlled sewing of free programmable safety-, functional- and decorative seams. For highest seam quality by tangential positio-ning of the sewing head in any direction (modular machine concept) All airbags (depending on the size of the airbag several airbags...

 Open the catalog to page 9
Segment Brochures "Airbag"-11

CNC-Nähanlage mit feststehendem Nähkopf für servo-motorisch gesteuertes Nähen frei-programmierbarer Sicherheits-, Funktions- und dekorativer Nähte (modular gestalteter Maschinenaufbau). Nähkopf wählbar: PFAFF 3590, DA M-TYPE oder H-TYPE CNC sewing unit with stationary sewing head for servo-motorically controlled sewing of free programmable safety-, functional- and decorative seams (modular machine design). Sewing head selectable: PFAFF 3590, DA M-Type oder H-Type Curtain airbags (depending on the size of the airbag several airbags can be produced in one template) Sewing of free programmable 2D-geometries...

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Segment Brochures "Airbag"-13

CNC-Nähanlage mit feststehendem Nähkopf (KL 300) oder mit 360° drehbarem Drehkopf (KL 301) für servo-motorisch gesteuertes Nähen freiprogrammierbarer Sicherheits-, Funktions- und dekorativer Nähte (modular gestalteter Maschinenaufbau) For all areas of the airbag manufacture Inflator- and deflator openings Sewing around the flange drillings to avoid tearing Sewing on of reinforcement parts and tether tapes Für alle Bereiche in der Airbagfertigung Ein- und Ausströmöffnungen Nähen um die Flanschbohrung zur Verhinderung des Ausreißens Aufnähen von Verstärkungsteilen und Fangbändern • Sewing area:...

 Open the catalog to page 13
Segment Brochures "Airbag"-15

Frei programmierbare CNC-Anlage zum Silikonauftrag auf Airbaggewebe. Die Kopfplatte ist in axialer Richtung verfahrbar, mittels Vakuum wird der obere Teilezuschnitt angehoben und nach dem Silikonauftrag positionsgenau platziert. • Silicone apply on curtain airbags up to 3,500 mm length • Positioning of the cuts with loading aids in the table as well as fixation with vacuum suction unit in the table and the lid • The size of the operating area allows to manufacture several airbags in one work process • Silikonauftrag auf Curtain-Airbags bis 3.500 mm Länge • Positionierung der Zuschnitte mittels...

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Segment Brochures "Airbag"-17

• Closing of round driver and passenger airbags • Schließen von runden Fahrer- und Beifahrer-Airbags • Sewing work station in compact design ensures maximum process reliability and repeat accuracy • Standard sewing head (double lock stitch or double chain stitch) • Diameter of the sewing field: 400 mm up to 1,000 mm • Easy exchange of the material fixation • Integrated material withdrawal device • Seam diameter: min. 550 mm, max. 850 mm • Sewing speed: up to max. 3,000 stitches/min. • Touch-Screen panel to enter all relevant product parameters • Automatic, pneumatic thread separator (hot wire)...

 Open the catalog to page 17
Segment Brochures "Airbag"-19

• Closing of the outer seam at passenger-, side- and knee airbags as well as further airbag applications (asymmetrical form) • Schließen der Außennaht an Beifahrer-, Seiten- und Knieairbags sowie weitere Airbag-Applikationen (in asymmetrischer Form) • Transfer- and material fixation unit ensure a reliabe and repeatable work process • Sewing area: from 380 mm up to 1,000 mm • Sewing head selectable: DA 195 (1-, 2- or 3-needle double chainstitch) or DA 767 (1- or 2-needle lockstitch) • Standard sewing machine top, pivot and movable mounted • Automatic material transfer- and discharge system • Easy...

 Open the catalog to page 19

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*Prices are pre-tax. They exclude delivery charges and customs duties and do not include additional charges for installation or activation options. Prices are indicative only and may vary by country, with changes to the cost of raw materials and exchange rates.