Quilting machine that unifies the quilted material by quick sewing of various multi-needle patterns
The only vertical single-needle quilting machine with 4 independently moving sewing-heads, guarantying a perfectly quilted closed frame over the panel´s perimeter
These features make the ClevOne a key tool in achieving a strong competitive advantage allowing to adapt to fast-changing trends in the mattress industry.
QUILTING MOTION SYSTEM
A continous flow and control of the input material permits to achieve a high pattern accuracy, independently of materials and thicknesses.
Doubles productivity in framed patterns with 4 and more motifs.
Accepts a wide range of materials and thicknesses, between 1 - 8cm, thanks to the exclusive and adapted development of the sewing-heads.
Enlarges and eases production possibilities, in relation to materials, thicknesses and patterns.
Enables quilting at high RPM, delivering a strong and reliable seam.
INDUSTRY 4.0. READY
The integration of an advanced electronic architecture enables us to comply with the Industry 4.0 requirements: connectivity, modularity and energy efficiency.
Its four sewing heads with independent movement, moving along the transversal carriage, increase the production of multi-needle drawings up to 2.5 times
Set up your ClevOne.
SEWING RAIL SYSTEM
Eases fabric changeovers by allowing the operator to complete this task ergonomically. The rail system is complemented with an auxiliar handy sewing machine that provides a fast and solid seam, reducing interruptions in the manufacturing process.
SMART SEAM MONITORING SYSTEM (BOBBIN CASE)
Assures the seam quality by monitoring the thread consumption, and detecting thread breaks; which avoids quality issues in the finished mattress.
Communicates and synchronises the work-flow between ClevPanel and ClevOne (multi-head quilting machine), by processing a single production list introduced into the ClevOne´s HMI dashboard, including lateral and cross-cutting ClevPanel´s sewing-heads, guarantying a panel with a centred pattern.
The current industrial revolution, Industry 4.0 and digitalisation of processes, has motivated us todevelop a powerful software that enables companies to manage their quilted panel production, by connecting different departments and users, feeding customised and valuable information to each user.
This management production module, focuses on easing the day-to-day of supply and production managers, improving management and control over the panel quilting process, as it transforms customers´ orders into production lists, transferred digitally and in real-time. To the allocated panel manufacturing line. These lists are smart and dynamic as they look to optimise resources and reduce changeovers. Interaction between ClevOne and its users, allows to follow-up production in real-time and generate reports for the decision-making process.
Completes two processes into one cutting and sewing of a quilted panelare completed simultaneously over the panel perimeter, delivering an important reduction in the manufacturing times and input costs, since it eliminates transitional processes and the exceeding edge between panels, needed otherwise for the manual overlock.
ClevPanel´s sewing-heads,exclusively developed, adapt automatically and accuretely to the requested panel measures (between 60-220cm and 140-240cm), working with thicknesses accepted by ClevOne (between 1-8cm), that delivers a perfect finish panel and eases the closing of the mattress.
The high level of integration between ClevOne and ClevPanel allows to manage a production list from a single dashboard.
Automatic stacking machine for panels that contribute to greater automation of the manufacturing line, fully integrated and synchronized with our Control Panel, controlling both machines from the same control screen.
Automatic stacking machine that contributes to a higher level of automation,with an integration and synchronisation with the ClevOne and ClevPanel, which enables the operator to manage both machines from a single HMI dashboard.
The ClevStacker piles panels up in different working modes, and up to 2 metres high without operator´s interaction for roughly 30 minutes, thus reducing product manipulation and eliminating repetitive tasks.
Own exclusive sewing-heads to deliver a high performance with an excellent seam
HIGH PERFORMANCE, OWN AND EXCLUSIVE SEWING HEADS
Since our beginnings, we have considered that development and adaptation of sewing-heads to the specifics of their tasks, are key to achieve the needed flexibility in the production. Delivering a high quality seam and pattern accuracy, when working with a large range of thicknesses (between 1-8 cm).
Research and development by our engineering team has resulted into a solid sewing system, built with a set of mechanical element with the purpose of giving response to a demanding market, challenging the production process day by day with new and thicker materials.
Powerful architecture to challenge high production demands.
QMS “Quilting Motion System”
Quilted material flows vertically, through this new system that, synchronised with the transversal movement of the 4 independent sewing-heads achieves a high pattern and frame accuracy.
Intuitive design creation
ClevDrawin´is a designing software to create patterns for quilted panels before loading them into the ClevOne. Provides full control over the panel pattern creation, with a large range of possibilities.
An easy interface that assists in the creation from scrap and in the modification of a quilted pattern.
Patterns can be assorted in 3 types, depending on the number of sewing-heads that participate simultenously in the quilting process:
AUTOMATIC FRAME GENERATION
Focuses on framed patterns, assisting users with the creation of frames by introducing basic parametres.
COMMAND CUSTOMIZING ORGANISATION OF SEGMENTS
Aids to optimize quilting pattern quality and manufacturing times by avoiding quilting gaps.
Allows to edit the sewing-heads settings within the pattern, such as: rpm, stitch length, … etc.
Overlaps a selected image (fabrics and drawings) by placing it in the background, easing the creation of a pattern, and simulating it as a finished mattress panel.
Verifies whether the pattern is configurated correctly or changes must be applied before launching it into production.
PATTERN WORKING FLOWAND MEASURES
Shows each segment´s order and direction, in which the sewing-heads are to complete the pattern.
Management & production control
Automate and connect with your quilted panel manufacturing, providing efficiency and flexibility.
The current industrial revolution, Industry 4.0 and digitalization of processes, has motivated us to
develop a powerful software that enables
companies to manage their quilted panel production, by connecting different departments and users, feeding customized and valuable information to each of them.
Interaction between ClevOne and its users, allows to follow-up production in real-time and machines running time and generate custom-made reports, assisting to the decision-making process.
The software enables users to create references according to their characteristics, (size, materials, patterns and quilts),
that can be used as tags in order to apply filters.
The production module eases production management and planification by importing (csv) or creating new orders.
Customers´ orders can be allocated with priorities or delivery dates and times, which might be used for organizing the production lists.
Production lists are transferred digitally and in real-time to the designated quilted panel production line. These lists are automatically arranged in an efficient manner to optimise resources and reduce changeovers.
By modeling the references, the ClevOne can follow-up consumptions and foresee material changes, notifying the operator and improving machines running time.
HMI Human Machine Interface
Maximum control and intuitive
Our HMI allows the the operator to interact directly with the ClevOne by loading ClevDrawin´ created patterns, that include ClevOne´s quilting parameters, such as the
number of sewing-heads that participate in the pattern quilting process, as well as the measures.
OFFERS TWO WORKING MODES:
A. Manual Introduction:
Users introduce manually patterns and unit quantities for production.
B. Automatic Introduction (ClevDynamics):
Our production manufacturing module enables users to import production lists automatically, which is organised in a smart and dynamic manner, optimising resources and reducing manufacturing times by arranging production according to preferences: measures, materials and patterns.
Our HMI enables control and accessibility to the moving components of the ClevOne, as they are all electronically connected. Modes:
Production: operator may move manually all elements that take part into the feeding and quilting system.
Maintenance:technicians have access to all moving elements independently to complete machine´s check-ups.
The HMI gives access to technicians when adjusting the synchronism of the sewing elements (needle and bobbin-case).
Through these settings, ClevOne gives technicians, hassle-free alignment of the two-independent sewing-blocks (needle and bobbin-case), in each of the 4 freely moving independent sewing-heads.
ClevOne is integrated with a useful functionality for the operator to assure a centered input material, as the HMI allows to move the sewing-heads to find its border limits, in order to start the pattern centered.
QUILTING MACHINE FOR THE MATTRESS INDUSTRY
Total quilting time:
96 seconds / panel.
* For this pattern
* Includes a sewing mark for ClevPanel´s cutting command.
Stitching speed: 2400 rpm
· Internal frame at 5 mm.
· Internal motifs (x12) at 3 mm.
Electrical installation: 3 p + tt
Phases voltage: 400 Vac
Minimum cable section: 10 mm
Power supply: 5 kW
· CO: 15 kW
· CO + CP: 20 kW
· CO + CP + CS: 22 kW
MACHINES DIMENSIONS (L x W x H):
· CO: 6400 x 5800 x 2300 mm
· CO + CP: 11400 x 5800 x 2400 mm
· CO + CP + CS: 14500 x 5800 x 2600 mm
· CO: 7400 Kg
· CO + CP: 9600 Kg
· CO + CP + CS: 10400 Kg
· CO: 150 l/min
· CO + CP: 230 l/min
· CO + CP + CS: 250 l/min
Downstream air pressure: 6 bar
· Width: up to 240 cm.
· Thickness: 1 – 8 cm.
· Filling: up to 5 layers
· X4 independent sewing-blocks
· Bobbin-case XXL
· Automatic lubrication
· Working speed: up to 3000 rpm.
· Stitch-distance: 1 – 6 mm.