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File - Dixie Sewing Machine 1-800-289-1554

1. PFAFF PFAFF Industrie Maschinen GmbH Postfach 3020 D 67653 Kaiserslautern K nigstr 154 D 67655 Kaiserslautern Telefon 0631 200 0 Telefax 0631 17202 E Mail info pfaff industrial com Gedruckt in der BRD Printed in Germany Imprime en R F A Impreso en la R F A
2. eeenee 2 6 2 09 01 Requirements accnsnananaannnnnnannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnnnen nennen nennen 2 6 2 09 02 Principle eau 2 6 2 10 Configuration in Docu software and machine controaller 2 7 2 10 01 Detection of the docu seam ALA nr 2 7 2 10 02 Language selection uuaeaneaanannnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnenenennnnnnnnnnen nennen nenn 2 7 2 10 03 Teach in the stitch regulator position PFAFF 3715 2 essssssnssnen 2 8 2 10 04 51216 9117911001 106 12 scasccesnnssasacnaceiensccseuiedndpestsnadincanhdactieasaapatdanandnddiannataniaciadeeniewentasedes 2 9 2 10 05 Parameter Configuration SettingS ccesseeessssssnnnnnssssennnnnnenssnennnnnnennennnnnnnennnnnnn 2 10 2 10 06 Adjustment of thread force thread tension eennennennnnnnn 2 11 2 11 Scanner instalation reae tr a Fa A re 2 11 3 Operaatio EE 3 1 3 01 How the Docu Seam System work 3 1 3 02 Password H 3 2 3 03 Pathi for seann MNES asserena e A EE 3 4 3 04 Saving docu seam files on floppy disk Ion 3 4 3 05 Beleeg 3 5 3 06 allen Det 3 7 3 07 Display FUNCTIONS okisi nanain eaman aa Enae EAEAP EEEE ALERE AEDE EE HEA EREE 3 11 3 08 Measurement of static thread force ann 3 15 3 08 01 Measurement of static force on the needle bread 3 15 3 08 02 Measurement of static force on the Dobbin bread 3 17 3 09 eebe eegene Eege 3 18 PFAFF Contents EE e ie a e EEN Chapter Page 3 09 01 De
3. Installation 2 10 03 PFAFF Docu Seam System Configuration Language Stitch regulator deutsch SC engish Saving the stitch regulator position francaise ch Ip Zero position of stitch regulator 0 00 _ Input of zero position 0 00 Adaption of stitch regulator EP End position of stitch regulator 0 Fig 2 01 Teach in the stitch regulator position PFAFF 3715 2 see fig 2 01 Set both adjusting dials for the stitch length to 0 Turn the main shaft to take over the mechanical gear position Enter the displayed stitch regulator position in the field zero position of stitch regulator into field Input of zero position Press Return key Set both adjusting dials for the stitch length at the maximum position Turn the main shaft to take over the mechanical gear position Change the preset value of 320 in the field Adaption of stitch regulator with the mouse using the arrow symbols so that the End position of stitch regulator has the exact value 100 Press the Return key Clicking on the button Save data the entered values are saved For teaching in only a new stitch length open the function Stitch Edit on the docu screen see chapter 3 09 05 To deactivate this function set the Adaption of stitch regulator to 0 PFAFF Installation 2 10 04 Service information The stitch regulator potentiometer is installed with a resistance value o
4. 14 on Fig 3 07 O The full scale values will be adopted both for display on the monitor and for the i bar graph display PFAFF Operation 3 07 Display functions The system offers a whole series of data which are displayed on the screen by the display functions 4 5 6 7 150 75 8 0 j 7 i J Gro 400 117002 9 10 11 12 13 14 15 16 17 18 2019 28 4 I 100 250 500 750 1000 1250 1500 29 i A 200 400 600 800 1000 1200 Time ms Fig 3 08 1 Status display This function displays the current status of the program red display program not yet started green display program running PFAFF Operation 2 Thread force diagram As well in position Test seam as in Docu seam selectable with slider F2 the thread force values of the executed stitches are indicated These values represent the max thread force during stitch formation means when the take up lever is in the upper death point Each sin gle stitch can be identified as a real numeric value in the thread force table 17 These values are saved in the corresponding seam file on the PC see chapter 3 12 04 3 Actual label With this function the current label name process name loaded is displayed All process parameters are downloaded when reading the label name settings label text 4 Docu seam area This shows whether the machine is currently in the docu seam area or not Green display docu
5. Operation Calling existing label names sewing process parameters are saved under this name the corresponding scan data settings are loaded automatically If there is no cycle input you are asked only once for the scan data after system start Starting the program you are asked for scanning your components In case of scanning new parts with new codes at the beginning of anew production processs these scan data do not match with the loaded label of the old sewing process Now entering EXIT you can call the corresponding label selection Before the sewing process you are asked to scan this can be by passed by entering EXIT if there are no pieces available at the work station now a new label selection can be executed Thread cutting indicates the end of a sewing process If a new order must be started new materials new threads etc the Docu System needs these new data in connection with the corresponding label see chapter 3 09 06 3 09 08 3 09 11 If an already existing label is selected for another sewing process the corres ponding sewing parameters are loaded automatically After preparation for a new sewing process the next scan operation is asked corresponding to the selected label with its corresponding scan data O The handscanner can also be used to enter manual input like passwords and i codes using barcode 39 PFAFF Operation Detecting the Docu Seam Area The area of monitoring the seam can be
6. representative value of thread force for this seam section is indicated in field Actual PFAFF Operation value In case of deviation between actual value and setpoint the thread force is regulated and corrected automatically If setpoint and actual value are close together switch to Docu seam the ascertained stimulus control electrical value for adjusting thread force is downloaded This value is attached simultaneously to the actual sewing process defined by label name Needing this sewing process again after a certain time loading the corresponding label name the necessary thread force is readjusted automatically too means the saved process parameters are reloaded and reproducibility is ensured Remark Heavy corrections to the thread force are detected by the Docu Seam System means a stimulus control deviation of 40 related to the required and previous loaded value leads to a warning information on the screen The operator gets an information that there is any reason for a heavy correction of the thread force It is commendable to check thread guides eyelets thread quality etc 7 Stop F1 By calling this function the program is stopped status red After this the WINDOWS platform can be reached by pressing the key F12 For PFAFF 3715 1 using the machine panel the configuration must be set to 9 if the selection slider is not positioned on Docu seam see chapter 2 10 05 Parameter Con figuration
7. 2 opens where additional inputs are possible Fig 3 02 PFAFF Docu Seam System Setup level 2 Functions C Pfaff Seam file Fig 3 02 3 2 PFAFF Operation Password 1 Clicking on the slider with the left mouse key it is moved up and the window Password Level 1 opens Fig 3 03 Password PFAFF can be changed into a user password Using password 1 highest priority you get access to all safety areas and only a person responsible for the whole system should get this password PFAFF Docu Seam System Password level 1 Fig 3 03 Password 2 Opening the window for password 2 in setup level 2 a password list for level 2 Fig 3 04 is displayed Up to 5 substitutes of password 1 may be entered Entering password 2 in setup level 1 there is no access in level 2 for the inputs of password 1 and password 2 The other selections of setup level are released PFAFF Docu Seam System Passwords for level 2 Fig 3 04 PFAFF Operation 3 03 3 04 Password 3 Opening the window for password 3 in setup level 2 a password list for level 3 Fig 3 05 is displayed The user may enter 20x6 characters to get access on the sewing process for example 2 characters for the operator 2 characters for the plant no 2 characters for the machine no The Status LED field indicates 1 out of 20 passwords according to the actual entered password 3 Now the screen indicates
8. F12 Windows will be Shut down automatically Nevertheless if you want to jump to the Windows main screen e g configure DS Setup press F1 to stop the Docu program After pressing Alt Esc the start bar is visible Clicking on Start Programs Windows Explorer folder PFAFF and DS Setup password 1 or 2 must be entered to open the Functions and remove the slider Auto WIN Exit to Red After clicking on the key return you jump back to Setup level 2 Clicking on the key Windows the program DS Setup is closed and the Windows Explorer is indicated After closing the Explorer the Docu main screen is displayed again Now shut down Windows by pressing F1 and F12 to read the new setting from Auto WIN Exit when the system is restarted Red This function is deactivated means a program stop by pressing F1 and F12 switches to the Windows main screen PFAFF Installation 2 08 2 08 01 Label Printers Do not select WINDOWS Printmanager After installation the printers must be selected as default printers The PC must be re booted Gemini T Label printer Connect the printer as default printer to the parallel interface LPT 1 of the computer Install the driver software under WINDOWS 98 as described in the printer manual Setting the printer parameters Call up the Gemini symbol with a double mouse click The Gemini Control Panel opens Printer select Setup Tharo Gemini opens Set Unit to mm and type in 155 0 as Label
9. No AA 300 110 SW 3 30 PFAFF Operation 3 09 13 Seiko Smart Label Printer 220 Supplier Inmac Micro Warehouse Postfach 1280 65433 Fl rsheim Telephone 0180 5237266 Telefax 0180 5228229 Label 23mm x 89 mm Inmac No BAC 7460 Scanner function To recognize and check the sewing process components threads fabrics etc you can use this scanner function A comparison of the preset and acutal data is executed the sewing process is only unlocked if the data comparison was successful and scan data are saved then in the corresponding seam file OK or NOK For every sewing process the corresponding label must be selected and configured To open the scanner function for data input click on the button Scan data of this configuration screen There are 10 rows available to enter up to 10 data Text Enter clear text description for example Needle thread 1 Code Only capital letters and numbers no spaces must be entered for example NT1 Cycle This is a setting which means after how many docu seams a new scan operation must be executed for example 15 If the input is 1 the scan operation must be executed after each docu seam Clicking on the button return you leave the scanner function and the settings are saved automatically together with the selected label name PFAFF Docu Seam System Text Code Cycle Capital ER numbers mmm mm CC CC CC CC CC Fig 3 20 PFAFF
10. Value LLV 300 cN Option F5 2 F6 50 cN F7 50 cN PFAFF Operation If the High Limit Value is set to 600 cN interrupted red line and the Lower Limit Value is set to 300 cN interrupted red line and 2 deviations are allowed the new sewing results may be within the new High Limit Value of 600 cN 50 cN 650 cN bold red line and the new Low Limit Value of 300 cN 50 cN 250 cN bold red line Each measured thread force which leaves the exceeded tolerance range of 250 cN to 650 cN immediately leads to a NOK seam This function leads to a more flexible system and can be adapted to more different operations with the focus on an exact definition of the sewing process itself to increase the number of OK seams Blinking of the different signs leads to a better failure analysis in case of leaving the preset tolerance range As long as the input at Option is still 0 no inputs at F6 or F7 are possible The entered values can be saved by pressing lt Return gt the input is deactivated again indicator red 6 Controller F8 After calling this function two different inputs are available if the input is active 1 Electrical adjustment of thread force To enter a value move selection slider F2 to Test seam Enter a numeric value for the thread force of 0 100 within the input field F8 Sewing tests have to prove whether the correct thread force has been adjusted Switching from Test seam to Docu seam the correspon
11. be simulated by stitching off a further test seam PFAFF Docu Seam System BT e Stop 79 001 400 117002 Fig 3 13 Call up the Selection field with lt F2 gt Select the function Test seam using the lt arrow keys gt or the mouse Stitch off the seam area During the sewing procedure the thread force occurring in every individual stitch is displayed on the bar graph 1 from green to red unless a real error has occurred When stitching off a test seam the display elements 2 and 3 should not change A check of the thread force values in the table is possible Correct the limit values if necessary 3 20 PFAFF Operation 3 09 04 Monitoring the number of stitches calculated stitch length Click on the slider in the panel Stitch Edit and move it to Y for yes The input window Selection opens PFAFF Docu Seam System Fig 3 14 Click on the key Seam length Stitch length the panel Monitoring the number of stitches opens PFAFF Docu Seam System Monitoring the number of stitches Fig 3 15 The 4 input fields are activated by clicking on with the left mouse key or by pressing the TAB key These numerical values can also be increased or reduced by clicking on the corresponding arrow fields Enter the length of the docu seam area in millimeters in the field seam length PFAFF Operation Enter the required number of
12. docu seam can be simulated here parameter 683 I or configuration 10 remains neither a label is printed nor the identification number with data file is created Test is written into the indicator LED Docu Seam Area Only in Test seam inputs for panels F3 F8 are possible calculated which does not correspond to the correct preset values therefore In case of thread break in Test seam a new stimulus control setting is enter manually a new setpoint Determining limit values PFAFF Docu Seam System sw 1 32 Seu 0 98 Stop Version 73 001 400 117002 Fig 3 11 e First of all the measuring ranges for the thread force and the time axes should Il be selected appropriately and the static thread forces for the needle and bobbin threads should be established or adjusted Call up the Selection field with lt F2 gt Select the function Test Seam using the lt arrow keys gt or the mouse Stitch off the seam area using the min and max speeds for the docu seam area During the sewing procedure the thread force occurring in every individual stitch is displayed on the bar graph 1 Then the values are indicated in thread force table 2 PFAFF Operation 3 09 02 Setting limit values After the maximum or minimum thread force by stitching off the test seam are established see Chapter 3 09 01 Determining limit values the limit values for the thread force can be entered P
13. files are only saved in PC2 If PC2 cannot receive data a short warning is displayed on the screen data are saved automatically on PC1 Docu PC in path C PFAFF Seamfile If no path for seam files was created in setup level 2 seam files are saved automatically in path C PFAFF Seamfile information can only be reset using password 1 or 2 Depending on the configuration of functions in setup level 2 a network error Configuration in Docu software and machine controller Detection of the docu seam area The docu seam area can be activated and deactivated by knee switch fotocell or seam pro gram see chapter 3 10 Language selection Factory settings in program DS Config exe already select the language Changing the language here you have to save the stitch regulator position for PFAFF 3715 2 see fig 2 01 Doubleclick the icon DS Config exe to open this program Move the slider with the mouse to the corresponding position Click on the button Return The selected language is saved If only the preselected language has to be changed use the following procedure Open file manager function n C PFAFF open the file poti ref txt with a double click The contents of the file are displayed the right hand number group indicates the language 0 00 German 3 00 Spanish 1 00 English 2 00 French Enter the appropriate number close the Editor function and start the docu seam program PFAFF
14. saved in other folders they must be opened too Labels of NOK seam files are not printed O i Label copies automatically get the additional printout Copy If the key combination Ctrl Shift F1 was unlocked in the function configuration setup level 2 the last still saved label can be printed 3 09 11 Loading a label name from external device This function can be released or blocked in the setup program see chapter 3 05 If this function is used a superior master PC network installation Ethernet can download a new label name includes all necessary sewing parameters into the file Label ID C Pfaff Label ID txt The new preselected label name has to exist already on the Docu PC A selection of a new label name can be executed only within the same label format A new label name is downloaded always after finishing a complete sewing process means after thread cutting 3 09 12 Information for ordering the required materials Gemini T Printer Supplier Dalektron GmbH Hainer Chaussee 55 63303 Dreieich Telephone 06103 86051 Telefax 06103 88976 Label 45 mm x 155 mm In rolls Tyvek permanent with heat transfer foil Order No AA 300 050 SW Label 90 mm x 48 8 mm In rolls Tyvek permanent with heat transfer foil Order No AA 300 090 SW Label 90 mm x 35 5 mm In rolls Tyvek permanent with heat transfer foil Order No AA 300 090 SW Label 110 mm x 45 mm In rolls Tyvek Type D 281 0 with heat transfer foil Order
15. seam number date time Identification number in addition with barcode Definition 6 digits for customer input A digits for the year 3 digits for the day of the year 4 digits for Docu seam number 1 digit for cross check number Number of labels 0 9 Gemini T 90 mm x 49 mm 01 Label output Clear text 3 rows for customer data Label name seam number date time Identification number in addition with barcode Definition 2 digits for the year 3 digits for the day of the year 4 digits for Docu seam number 1 digit for cross check number Number of labels 0 9 Gemini T 90 mm x 49 mm 02 The new version 90 mm x 49 mm 02 with a sewing space of 20 mm offers a manual input field of 2 characters numbers and capital letters and contents the following items 3 rows for clear text 1 row for label name and seam number 1 row for date and time 1 row for identification nr in barcode option cross check nr 1 row for identification nr in clear text The Identification nr is defined as follows 2 digits for manual input 2 digits for the year 3 digits for the day of the year Adigits for the Docu seam number 1 digit for the cross check nr Option only in Barcode visible Number of labels 0 9 PFAFF Operation Gemini T 90 mm x 35 mm Label output Clear text 3 rows for customer data Label name seam number date time Identification number Definitio
16. stitches in the field setpoint of number of stitches Seam length number of stitches ideal stitch length The stitch length resulting from this calculation is stored in the seam file Enter the allowable tolerance for the number of stitches in the docu seam area in the fields number of stitches Example Seam length 250 mm Setpoint no of stitches 50 number of stitches 2 Result 51 counted stitches in the docu seam area Le the docu seam is in order because the tolerated number of stitches was not exceeded The average stitch length was therefore 4 9 mm 250 mm 51 This is stored automatically as the result in the seam file The indication panel for the stitch length remains green To save these input values click on the key return with saving If the previous values are to be saved click on the key return without saving O If the value 0 is entered for the seam length the function monitoring the 1 number of stitches is deactivated 3 09 05 Monitoring the stitch regulator position In the case of sewing machines with manual adjustment of the stitch length with an adjusting dial an integrated sensor monitors the stitch regulator position for each stitch length The correct stitch length is determined by adjusting the adjusting dial or by making test seams Click on Stitch Edit and move to y yes Input panel selection opens Fig 3 14 PFAFF Docu Seam System Setpoint o
17. with the mouse or with the respective key 14 13 PFAFF Docu Seam System Bess force EI Time ms eWD 0 79 Seu 0 79 e Stop 668 ff Version R 79 001 400 11 002 Fig 3 07 3 4 5 2 1 Start F1 By calling this function the program is started 2 Input Esc This function enables and or blocks the input of limit values and the use of Option Input display red input not active Input display green input active 3 High limit value F3 After calling this function when Input is activated see above the high limit value for thread force can be changed After pressing lt Return gt the newly entered limit value is adopted and saved At the same time Input is deactivated again input display red 4 Low limit value F4 After calling this function when Input is active see above the low limit value for thread force can be changed After pressing lt Return gt the newly entered limit value is adopted and saved At the same time Input is deactivated again input display red 5 Option F5 F6 F7 After calling this function when Input is active see Point 2 Input the number of permissible exceedings can be entered that is the number of individual stitches whose thread force may lie outside the prescribed limit values This extension now allows the user to define the area of limit value exceedings very exactly Example High Limit Value HLV 600 cN Low Limit
18. Des 3 37 3 12 06 EE 3 37 3 13 Examples of seam programming eeeessssesssssssennnnnnssennnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnn 3 38 3 13 01 PEAFFSTISSI Ee ee 3 38 3 13 02 General information on seam programming on the PFAFF 3715 1 sessies 3 44 3 13 03 ECK A 3 45 3 13 04 General information on seam programming on the PFAFF 3715 21 3 46 4 EXTENSION ee een 4 1 4 01 Coupling of Bobbin Thread Monitor with Docu bt 4 1 4 01 01 Unlocking with password 1 ele 4 1 4 02 Exit function tor label 110 x 45 MM EE 4 2 PFAFF Proper use Proper use The PFAFF Docu seam system is a supplementary quality assurance device with which safety oriented seams can be observed and documented during the sewing process Process parameters are aquired online by a measurement device during stitch formation data are analyzed and documented The result ist a good bad information about the sewn seam strength On a seam file all important process parameters are stored automatically Simultaneous to this operation a label is printed including these data in clear text and barcode This label is sewn into the seam and makes retraceability possible for each seam Any use which is unauthorized by the manufacturer is regarded as contrary to the instructions The manufacturer does not accept responsibility for any damage caused by improper use Using the device according to the instructions also involves compliance with all operating measures provid
19. FAFF Docu Seam System Be iF Sei N en 400 11 002 3 2 1 Fig 3 12 The limit values should be set at an appropriate and safe distance according IN to normal sewing practice from the thread force values measured in the test seam Activate the input mode by pressing lt Esc gt The input display 1 changes from red to green If key Caps Lock is activated key lt Esc gt deactivated Activate the input field for the high limit value with lt F3 gt Enter the high limit value Activate the input field for the low limit value with lt F4 gt Enter the options with lt F5 F7 gt Confirm the input limit values by pressing lt Return gt The altered limit values are adopted and stored on the hard disk The input display 1 changes again from green to red J J J Enter the low limit value J J In a similar fashion to the input of limit values the input of permissible exceedings can if required be carried out in the selection field 2 Option S The occurrence of exceedings becomes more probable with a low tolerance 1 level in the limit values An evaluation of the seam quality must determine whether exceedings are permissible at all The actual number of exceedings occurring is displayed in field 3 only active within the docu seam area PFAFF 3 19 Operation 3 09 03 Checking limit values The sewing procedure production with the adjusted limit values can
20. Height take care of your label size Do not select Continuous Material Select Landscape X Fast Print Label Printing Mode Select Options Printer Mode opens Select Batch Mode and set Presentation Position on 3 Select Thermal Transfer and set Heat Setting on 5 adapt if necessary Set Printer Speed 50 mm sec and Label Offset on 0 0 Select OK Tharo Gemini opens Select field and deactivate Always on Top Select field and close Close Gemini Loading the barcode Call up the symbol Fonts in WINDOWS Control panel Call up Add fonts Insert barcode disk and select disk drive A Double click Code 39 A list of fonts is displayed Double click Codedreineun Plain True Type Font is displayed Close function PFAFF Installation 2 09 2 09 01 2 09 02 Network Installation Instruction for self installation Requirements Ethernet standard IEE 802 3 NE2000 compatible WINDOWS 98 PCI Bus Additional BNC connector for coax cable T connector End resistor Definition PC1 Client Docu PC access to resource drive of PC2 PC2 Server External device shares resource drive for PC 1 Access to Docu PC is not permitted Principle Configuration Start of Network configuration Register card Configuration Add Client Add Manufacturer Microsoft Network Clients Client for Microsoft Networks OK Configuration of Network card Network Add Network card Add Select netw
21. PFAFF Docu Seam system User s guide For Software version 79 001 400 1 1 296 12 18 460 002 Benutzerhandbuch engl 10 01 The reprinting copying or translation of PFAFF Instruction Manuals whether in whole or in part is only permitted with our previous authorisation and with written reference to the Source PFAFF Industrie Maschinen GmbH Postfach 3020 D 67653 Kaiserslautern K nigstr 154 D 67655 Kaiserslautern Editing Illustrations PFAFF Dept TES Contents WEE Chapter Page 1 Proper use dissitigis irirna assine oaei in aei E Eii aeii a E iidr Eanair na EES esias Eii 1 1 2 LE E 2 1 2 01 System requirements uaaeeaannaanannnnnannnnnnnnnnnnnnnnennnnnnnnnennnnnnnnnnnnnnnee nennen nennen 2 1 2 02 Installation of driver software NI DAQ for WINDOWS isseesseieesiiseeiserieeerrerrree 2 1 2 03 NI DAQ Hardware Configuration 0c cccccccccccccccccessecetscesseseesescsessateeeseseesstesseiseesees 2 2 2 04 Install Docu Seam Program from CD 2 3 2 05 Linking the Docu Seam Program to Startup uceecnneenenneeeennneseennnnnn een 2 3 2 06 Locking the Windows function key 2 4 2 06 01 lut KEE 2 4 2 06 02 IKAWMIN OS ccs ee innen eines 2 4 2 07 Shut Down Windows automatically 0 cccccccccccecescssessesscsesescseceecessessateetetenetees 2 4 2 08 Ee 2 5 2 08 01 Gemini TABS egpter seed tEareeegdesgieegen deeg Eesen EES 2 5 2 09 Network Installation Instruction for self installation
22. a cable into keyboard Open WINDOWS Notepad Read installation codes from scanner manual Restore Default Wedge IBM AT Nationality English Operating Test 123456 displayed in Notepad Code selection for code 39 is read from scanner manual 1 Read Enter configuration 2 Read Standard Code 39 3 Read Exit and Save configuration PFAFF Operation 3 Operation 3 01 How the Docu Seam System works A sensor inserted in the needle thread course of the sewing machine determines the actually occurring tensile forces on the needle thread needle thread tension at every stitch during the sewing process The signals from the sensor are then evaluated in the PC via a signal input board and a data acquisition board and are displayed on a monitor on a user interface running under WINDOWS 98 The analysis of these signals provides information about the machine setting and the quality of every individual completed stitch The seam area in which the system is to be activated docu seam area is determined by seam program knee switch or photocell The docu seam system compares the established thread tensile forces with the previously entered limit values and gives an evaluation of the seam on the monitor In the case of a good seam a label can be issued if necessary using a printer with the relevant signal to the PC interface Moreover the docu seam system activates a skip stitch detection function and reacts on running
23. activated by 3 different modes see the following table Knee switch The operator has to press the knee switch to define the beginning and end of the docu seam area Fotocell Because of start and stop material flags the fotocell detects the docu seam area It is recommended to choose a specific size and shape for the material flags an equal sided triangle outside the seam with a hight of 15 mm The reflection area on the stitch plate must be lightly polished to secure a correct function If adaptions of the fotocell switching level are necessary use the yellow adjustment screw at the front side of the fotocell housing Flashing of the yellow fotocell LED means the material detection is instable Seam program stitch counter By entering seam programs complete sewing processes or only seam sections can be executed with the corresponding machine functions Detection of Docu Seam Area by means of Knee switch Fotocell Seam program Stitch counter PFAFF 3715 1 Select in operation Select in operation Select in operation mode Input the mode Input the mode Input the symbol Knee switch symbol Sensor Stitch counter fotocell PFAFF 3715 2 Parameter 994 Parameter 994 Activate operation Parameter 995 Parameter 995 mode programmed sewing by key T9 P M Parameter 994 Parameter 995 Do not connect the Knee switch fotocell to the motor controller H Refer to example o
24. alues are dependent on the speed it is useful to avoid changes in speed within the docu seam area This enables a better tolerance for the limit values and the number of seams classified as good increases The speed should be reduced 5 stitches before the docu seam area The machine stop after the docu seam must be programmed The machine then stops 3 stitches after the end of the docu seam Label printing takes place if necessary the label can be sewn in The next seam program can only take place after this procedure In the case of manual sewing the docu seam can be switched on and off by using the knee switch f adocu seam is classified as poor the sewing procedure can be ended or interrupted by switching over to manual sewing The key S on the operating panel has to be pressed to quit the error signal f the sewing process is to be started at certain seam sections the sewing positions and program positions must coincide If necessary the program must be set at the required starting point manually The needle must be positioned within the fabric at end of Docu seam and stop within Docu seam to prevent slippage or withdrawal of fabric Additional symbols on the Quick operating panel On the LCD matrix following signs appear at the postion x Docu seam area activated Error in docu seam o No watchdog function machine PC communication is interrupted m Manual sewing within a programmed seam activated
25. arcode visible Text Part code in ID barcode 3 rows for clear text 1 row for label name and seam number 1 row for date and time 1 row for identification nr in barcode option cross check nr 1 row for identification nr in clear text The identification nr is defined as follows 10 digits for customer specific input e g part code 2 digits for the year 3 digits for the day of the year 4 digits for the Docu seam number 1 digit for the cross check nr option only in barcode visible Number of labels 0 9 Seiko 28 mm x 89 mm Label output Clear text 3 rows for customer data Label name seam number date time Identification number Definition 2 digits for the year 3 digits for the day of the year 4 digits for Docu seam number Number of labels 0 9 S The cross check number Modulo 43 is not appended to the text identification i number but is printed with the barcode if the function was released in setup level 2 PFAFF Operation 3 09 10 Making Label copies To increase process security a separate program can be used if there is access on Password 1 or 2 The program DS Label Copy is started from the WINDOWS platform a list is displayed containing the saved seam files Clicking on the wanted seam file the label is printed The screen displays the question Another label copy No Program exit return to WINDOWS platform Yes List of seam files is displayed If seam files are
26. artup Click on Start with the right mouse key Click on Open Programs Startup Press Ctrl key and drag and drop the PFAFF Icon to Startup using the left mouse key Close shut down PC OK After Restart the Docu Seam Program is loaded and started automatically TL The screen has to indicate the following 4 PFAFF icons DS Config exe DS Setup exe DS Label Copy exe and DS11 exe 3 3 PFAFF Installation 2 06 2 06 01 2 06 02 2 07 Locking the WINDOWS function key In WIN 98 My Computer Control Panel System Device Manager Open directory keyboard Standard 101 102 key or Microsoft Natural Keyboard is indicated OK Add New Hardware Next Next No the device is not listed Next No Select Hardware types Next Hardware types click on keyboard Models Select Olivetti keyboard 102 key Next If conflict warning Next Finish Properties of General deactivate device user Click on Activate device Restart PC Yes The WINDOWS key is now locked in Docu Seam Program WIN 95 My Computer Control Panel Keyboard General Keyboard type is listed Change activate Show all devices Models Select Olivetti keyboard 102 key OK Close Restart your computer now Yes Shut Down Windows automatically This feature can be locked or unlocked in programm DS Setup by opening the Functions The meaning of the function slider Auto Win Exit is as follows Green After program stop by pressing F1 and
27. by T4 F4 Switching to the next programme takes place by pressing the foot pedal fully backwards Position 2 3 46 PFAFF Extension 4 Extension 4 01 Coupling of Bobbin Thread Monitor with Docu PC Coupling the Bobbin Thread Monitor 926 06 with the Docu PC leads to another monitoring method of the sewing process included with the Docu Seam System When the bobbin thread monitor detects that the preselected amount of residual thread is reached LED at machine is blinking in case of a correct preset of residual thread you can finish your running sewing process without stopping the machine Parameter 727 After thread cutting this bobbin thread alarm is evaluated and the sewing machine is blocked Error 9 on display Parameter 679 II The Docu screen displays the question Bobbin Thread changed After the bobbin thread was changed this operation must be confirmed by Pressing Key F10 or clicking on the Field F10 on the Docu screen with the mouse pointer After this confirmation Error 9 is deleted and the sewing machine is unlocked Parameters for PFAFF 3715 1 The option Bobbin Thread Monitor 6 can be activated deactivated in chapter 11 08 in the input menu at Switch Functions 1 of the sewing machine instruction manual To preset the still needed number of stitches after the 1 bobbin thread alarm select Counter 3 the option Delay thread monitor 4 of the sewing machine instruction manual Parameters fo
28. d scaling of the X axis is executed automatically depending on the number of sewn stitches This function can be released or locked in program DS Setup opening Functions and placing the slider Table on the corresponding position Green visible Red not visible PFAFF 3 35 Operation 3 12 02 3 12 03 3 12 04 Monitor After calling up the Monitor function the dynamic thread force signal is displayed on the thread force monitor In this way one has the possibility of a signal analysis of the dynamic thread force which gives indications of the quality of the stitch formation If the thread force analysis is used intensively in the Monitor function TL the signal form the curve can be stored on the screen by switching from Monitor to Save during recording the signal using arrow keys or mouse click Thread force table Every single stitch is listed in the thread force table too together with the corresponding thread force values in Test and Docu seam Seams with a maximum of 4999 stitches per docu seam can be processed It is possible to scroll through the table by clicking the mouse on the arrow keys at the side or by moving the slider Contents of the seam files Seam files for good and bad docu seams are saved with the following parameters on hard disk and or floppy disk or network Identification number contents of barcode cross check number password 3 part code seam number da
29. ding percentage value is accepted saved and is related to the actual sewing process defined by label name This ensures a correct reproducibility of the sewing process Pressing the Return key the new value is accepted and saved the input is deactivated again indicator red 2 Automatic electrical adjustment of thread force closed loop control Principle of controller loop This version shows a feedback control loop Setpoint Actual value comparator sensor control valve control device Contrary to electrical adjustment the automatic controller loop compensates the influence of external disturbance means changes in thread force by process effects are detected and compensated by automatic regulation This ensures a balanced distribution of the stitch related thread force values in the middle of the tolerance range drifting of thread force values is minimized and production of defective docu seams is reduced In position Test seam various sewing tests must be made to achieve a correct seam quality The ascertained thread force value will be loaded to Docu seam by switching the slider to this position and is related and saved to this actual sewing process defined by label name This ensures a correct reproducibility of the sewing process Operation To enter a setpoint of thread force the selection slider F2 must be positioned on Test seam Enter the thread force setpoint in cN into field F8 At the end of the sewn test seam the actual
30. e saved NOK is appended to the identification number Red No NOK files are saved Network File Green Deleting the error information and unlocking the machine is executed automatically after about 5 seconds Red Deleting the error information and unlocking the machine only by entering password 1 or 2 PFAFF Operation Option Green Input is unlocked Red Input is locked BT Change Green No confirmation of bobbin change Red Bobbin thread change must be confirmed by password 1 or 2 the machine is unlocked Setpoint actual value Green Input and indications are unlocked Red Input and indications are locked Scan Exit Green Execute Exit without password 1 2 Red Execute Exit with password 1 2 Auto WIN Exit Green Shut down Windows automatically Red No automatic Windows shut down Label name ext Green Reading the label name from external Red Reading the label name not from external Saving on floppy disk Green Saving data on floppy disk too Red No saving on floppy disk Click on return this configuration is save and left PFAFF Docu Seam System High limit value F2 Selection E L EH el GI Label Form Label Scan Stitch Edit EH ER ER Em GH Unlock machine SC reset daily NOK file Network file LO PR FH GH BT Change LO Rm Pm CO CU Le LL I mm em bm EE bemmes Fig 3 06 3 6 PFAFF Operation 3 06 Input Functions The functions can be called up by clicking
31. e to be selected with the use of the arrow keys Pay attention to the cursor Insert the desired stitch length Wl D The input is used for both stitch lengths If different values have to be entered ROLLER PRESSER 3 5 MM FEED WHEEL 3 5 MM VALID 0 8 MM 5 0 MM DIFF 1 MM Clear Jeee Lee Fig 3 26 Confirm stitch length input with Enter key Sea HE EE HERGES Fig 3 27 PFAFF 3 39 Operation Call up the function End of seam area Number key 9 WWE azarean DISS JAS C e Fig 3 28 Iess The function stitch counter is already switched on inverse By operating the function Number key 1 the menu for the input of the number of stitches is opened A 1 295 f 35 iG E SBOE T Fig 3 29 BR Enter the desired number of stitches Enter Confirm input with Enter key ES Fig 3 30 Enter Close the menu end of seam area with Enter key BEER BEEEEEGDDR Ener Fig 3 31 m To program the second seam area switch off the function End of program Number key 0 Enter Press Enter key to teach in the first seam area PFAFF Operation Program the second seam area docu seam area Inthe seam area the stitch length should be 5 0 mm the automatic stop function should carry out a stitch count 20 stitches the speed sho
32. e using the Monitor function Example Conflict ECP printer LPT1 OK Conflict warning Yes gt Ressource setting Device conflict DMAO3 used by ECP printer LPT1 OK Shut down WINDOWS start WINDOWS My Computer Control Panel System Device Manager Conflicting device Select ECP printer Resources manual configuration ECP printer LPT1 set on DMA1 no conflicting device OK close Start programs National Instrument DAO NI DAO Configuration Utility Correct configuration is indicated Next Configure OK File Save Exit PFAFF Installation 2 04 Install Docu Seam Program from CD Start Run Browse My Computer select CD drive PFAFF directory is listed Open PFAFF select Pfaffsetup bat Open OK Program is installed on drive C Start Programs WINDOWS Explorer Open directory PFAFF select small screen Click on Icon DS1 1 and drag and drop to desktop screen Close Explorer Arrange Icons Install PFAFF Icon click on with right mouse key Pop up menu is opened Properties Change Icon Browse In directory PFAFF double click on PFAFF ico OK Apply Close Start Docu Seam Program If taskbar appears on the screen do the following operation Close the program using keys F1 and F12 Start Settings select Taskbar amp Start Menu deactivate Always on top activate Auto hide Apply OK Restart the Docu Seam Program from WINDOWS 2 05 Linking the Docu Seam Program to St
33. ead the needle thread according to the machine class taking into account that the thread is passed through the thread force sensor but not yet through the needle Call up the Selection field with lt F2 gt If necessary adjust the measuring range for the thread force see Chapter 3 07 Display functions point 26 and 27 Fig 3 08 Select the function Thread Force using the lt arrow keys gt or the mouse A green text field 1 with instructions appears on the thread force monitor PFAFF Operation After the signal carry out at least 2 machine revolutions Machine stop at take up lever T D C Pull the needle thread evenly and slowly in the direction of the arrow until a red text field 2 appears on the thread force monitor The measured value can be read off the bar graph 3 and the display panel 4 If necessary adjust the thread tension knurled nut 5 and repeat the measuring procedure after the signal until the value for the thread force is correct rhythm once the measuring function has been initialised by the revolution of D The alternating procedure Measure read adjust takes place in a 6 second the machine PFAFF Operation 3 08 02 Measurement of static force of the bobbin thread Fig 3 10 Thread the bobbin thread through the thread force sensor and the take up lever depending on the
34. ed by the manufacturer PFAFF Installation 2 01 2 02 Installation The following described installations may only be executed by adequately N specialist personnell The danger and safety instructions on the machine itself are to be followed System requirements Hardware PC with Pentium processor 800 MHz or higher Disk drive 2 ISA slots Standard hard disk min 64 MB RAM min 14 color monitor Microsoft compatible mouse CD ROM drive Software Microsoft WINDOWS 98 Control panel settings High Color 16 bit Screen 640 x 480 WINDOWS 98 is a registered trademark of MICROSOFT CORPORATION USA Installation of driver software NI DAO for WINDOWS Attention The NI board must be removed from the PC out and must only be done for a new configuration After the PC is switched on the Docu seam program is started automatically D In the delivered condition the following installations have already been carried Depending on the driver version the CD starts automatically or must be called manually The CD drive could be D Manual calling or CD starts automatically Start Run Browse click on symbol My Computer Click on the CD drive Open NI dag D with double click Directory of the CD is listed Open Setup exe with double click gt D setup exe OK Open Install NI DAQ with double click NI DAO driver files Next Select Destination Directory CANI DAO Next Select Group is i
35. ed fault within the docu seam the machine is stopped now Error 9 or Stop symbol on the machine display the sewing material cannot be taken away because the needle is in the material an input field appears on the Docu screen for password 1 or 2 Af ter entering the correct password the error indication appears in the machine display the machine remains locked Quitting the error information on the machine display PFAFF 3715 1 key Enter Pfaff 3715 2 key S the machine is finally unlocked and the seam can be finished Output functions of the Docu Seam System The docu seam system offers various possibilities for the evaluation and further processing of stored information Thread force diagram The complete Docu seam can be displayed in a diagram with this function including the thread forces stitch by stitch You get an immediate summary about the homogeneity of your produced seam and you are able to check the distance to the limit values A sewing stop immediately indicates a thread force decrease while sewing over additional plies of material the thread force increases The more the sewing process is optimised to constant thread forces the less NOK seams are to be expected This function is a tool to make the sewing process itself and the sewing result visible If the selection slider F2 is positioned on Docu Seam this function is activated and scaling of Y axis thread force in cN is executed depending on preset limit values an
36. f 1000 300 ohm only PFAFF 3715 2 using a medium stitch length This is an electric voltage of 1 68V to 3 12V The actual value is the measured value displayed in the right lower corner of the screen Monitoring stitch regulator position This indication too can be used to find the correct assembly position If the synchroniser is dismantled exchanged or adjusted the starting position of the synchroniser must be taught in again only PFAFF 3715 2 In the operating field OC TOP activate key 10 TE Select parameter 700 Needle position 0 on the programming level B mechanical level Push pedal forward once Turn hand wheel forward and position the tip of the needle exactly on the upper edge of the needle plate Push pedal forward once again Deactivate key 10 TE Start sewing procedure 2 9 PFAFF Installation 2 10 05 Parameter Configuration Settings Enter settings on the control panel with display PFAFF 3715 1 Configuration Meaning 9 10 il D A Docu Seam monitoring no Selection slider F2 may be positioned on Test seam Save Monitor or Threadforce In this cofiguration the machine can be used without Docu Seam System Docu Seam monitoring yes Selection slider F2 has to be positioned on Docu Seam If this condition is not fullfilled a Watchdog function will block the machine a sewing operation is not possible PFAFF 3715 2 Gro
37. f seam programming chapter 3 13 PFAFF Operation 311 Sewing with the Docu Seam System After the limit values for the thread force have been established entered and tested production can be carried out monitored and controlled by system Fig 3 21 PFAFF Docu Seam System 750 EE EE E 675 600 1 525 450 375 2 300 3 225 ral 75 5 F 8 0 1 3 i up 072 e 0 72 488 Br Version 79 001 400 11 002 Call up the Selection field using lt F2 gt Select the function docu seam using the lt arrow keys gt or the mouse If the system is restarted beginning of operations a program autostart takes 1 place after the devices are switched on In this case the default values from the previous use are installed and the docu seam function is activated See chapter 2 10 Configuration in Docusoftware and machine controller Stitch off the seam As soon as the docu seam area is reached the seam monitor function is activated display 1 turns green On leaving the docu seam area display 1 turns red again the seam results are displayed Docu seam is in order The thread force diagram shows the sewing result stitch by stitch Display panels 2 3 4 and 5 are green PC interface receives a signal Seam is in order Docu seam number is increased by 1 and displayed in panel 2 The Docu seam OK indicator is increased by 1 Total number of stitches in
38. f stitch regulator position 59 Actual position of stitch regulator 59 Fig 3 16 3 22 PFAFF Operation Click on the key Stitch regulator the panel Monitoring the Stitch regulator position opens Fig 3 16 The resulting correct position for the stitch regulator is taken over as the setpoint by clicking on the function return with saving As long as the value of the actual position does not deviate from the setpoint by more than 4 after sewing the docu seam the stitch regulator position is considered to be in order i e the stitch regulator indicator is green and the setpoint and actual position are stored automatically in the seam file Q To deactivate the function Monitoring the stitch regulator position I the stitch regulator adaption must be set to 0 in the Configuration program PFAFF 3 23 Operation 3 09 06 Label sizes printer selection Click on the slider in the field Label Form and move it to Y for yes The input window for the label sizes opens PFAFF Docu Seam System v Gemini T 110 mm X 45 mm Fig 3 17 Open the menu by clicking on the arrow symbol Press the left mouse key and position the mouse pointer in the desired field Click on the key return The window Save As opens PFAFF Docu Seam System Speichern unter _2 x E Test G61 txt Speichen Custom Pattern txt Fig 3 18 Select your label as described
39. good docu seams Counter for bad docu seams The counter values can be changed or reset in this file O If new files get the name of already existing files aWINDOWS error warning is displayed on the screen PFAFF Operation 3 13 Examples of seam programming 3 13 01 PFAFF 3715 1 The seam to be programmed should have 3 seam areas and be stored with the comment docu under program number 7 Call up the operation mode ENTER An 30 Ba 3 WEE 3 DECH TAT e Fig 3 22 Z Call up the function Programming Number key 4 GES JIS ee Fig 3 23 Enter programm number 7 Confirm input with Enter key Display appears for entering comment EEE e COMMENT kb ABCDEFGH I 3 PHA Elke S Lee Fig 3 24 Select letter D Press right arrow key Select letter O ale Complete comment using the above method PFAFF Operation Confirm input with Enter key E y DEER Te E ee Fig 3 24 Program the first seam area before the docu seam The seam area should have stitch count 20 stitches and a stitch length of 3 5 mm for roller presser and wheel feed Call up the function stitch length Number key 4 WEE ROLLER PRESSER 3 0 MM FEED WHEEL 3 0 MM Ta S VALID 0 8 MM 5 0 MM DIFF 1 MM I DEER Fig 3 25 He Alle the roller presser and the wheel feed hav
40. has just been measured is displayed on the bar display The division of the scale adjusts itself according to the newly set full scale value 26 29 Scale If position Monitor is selected in panel Selection F2 scaling is possible Click on slider 26 or 27 for cN or ms and move upwards A slider for setting the full scale values of thread force 28 or time axis 29 appears on the thread force monitor Click on the needed scale value The slider moves to the selected full scale value and these values are accepted in the monitor and the bargraph Move the slider 26 and 27 down again 30 Monitor Selecting the position Monitor in panel Selection F2 the dynamic thread force signal is indicated For a detailed signal analysis change the measurement ranges 26 29 PFAFF Operation 3 08 3 08 01 Measurement of static thread force Besides the supervision of the docu seam area this system also offers the possibility of measuring both the needle thread tension force of the needle thread and the bobbin thread tension force of the bobbin thread without any additional device when the machine is stationary In this way you can have optimum reproducible values for setting the machine which can always be set precisely for every individual sewing process Measurement of static force on the needle thread ewD 139 Bh 139 top Fig 3 09 Thr
41. in Chapter 3 09 07 Label name label selection PFAFF Operation 3 09 07 Label name label selection Open the window Save As See Chapter 3 09 06 Label sizes printer selection Click on the desired label names if these exist Click on Save Text and information about the selected label are displayed To create a new label Enter the name of the label in the text field file name The cursor must blink in the input field N The label name must have 8 characters to which txt is appended automatically Click on Save The window for text input opens Do not install new directories because program access is done automatically to existing label directories 3 09 08 Text input for label printer All functions are explained with the example of the Gemini printer and with a label size of 110 x 45 mm PFAFF Docu Seam System rzum K ln 18 22 05 2001 Return AFF DOKU SYSTEM KL 3715 Return icherheit bei jedem Stich Enter Text mber of labels Text Identification barcode v Text Part code in ID barcode in Part code max 10 characters numb d capital letters I JABC1234DEF selected file C PFAFF Label G6 Test G60 txt Actual label Test G60 Fig 3 19 Activate the input fields by clicking on with the mouse the cursor appears in the appropriate field or by using the TAB key PFAFF 3 25 Operation After loading already existing label names all correspondi
42. loppy disk After inserting a new floppy disk the saving process is executed Release functions Move the slider Functions from red to green in setup level 2 Fig 3 02 and the screen Functions unlock lock opens Fig 3 06 Unlocking function means the slider on green locking functions means slider on red High limit value low limit value Option Fig 3 06 Green Input is unlocked Red Input is locked F2 Selection Scale Label Form Label Scan Stitch Edit Green WINDOWS can be opened Red WINDOWS are locked Label Copy Green Using the key combination Ctrl Shift F1 the label which is still in memory can be printed The label gets an imprint Copy Red Using the key combination no Label Copy is possible see chapter Making Label copies 3 09 10 Stitch counter incl thread force diagram Table Min Max u s Bargraph Docu seam no Green Indications are visible Red Indications are not visible Unlock machine Green After bad docu seam the sewing machine is not locked Red After bad docu seam the sewing machine is only unlocked by entering password 1 or 2 SC reset daily Green The seam counters file SC txt in path C PFAFF Counter are reset a 0 00 o clock Red The seam counters are reset to zero after reaching a total number of docu seams of 9999 Cross check no Green Across check number modulo 43 is appended to the barcode Red No cross check number is calculated NOK file Green NOK files ar
43. machine type Call up the Selection field with lt F2 gt Set the measuring range for the thread force at 100 cN see Chapter 3 07 Display functions point 26 and 27 Fig 3 08 Select the function Thread Force using the lt arrow keys gt or the mouse A green text field 1 with instructions appears on the thread force monitor After the signal carry out at least one machine revolution Machine stop at take up lever T D C Pull the bobbin thread evenly and slowly in the direction of the arrow until a red text field 2 appears on the thread force monitor The measured value can be read off the bar graph 3 and the display panel 4 If necessary adjust the thread tension screw 5 and repeat the measuring procedure after the signal until the value for the thread force is correct rhythm once the measuring function has been initialised by the revolution of D The alternating procedure Measure read adjust takes place in a 6 second the machine PFAFF 3 17 Operation 3 09 3 09 01 Test seam The necessary requirements for the docu seam area can be established by stitching off a test seam In the process the system saves the thread force of the individual stitches and displays the values on the thread force table 1 at the end of the test seam The maximum or minimum occurring thread forces are displayed in the Min Max panel These thread forces serve as the basis for setting the limit values The original
44. n 10 Low limit value In this panel the adjusted value for the low limit value is displayed This display serves as an adjustment aid to recognize during a test seam whether the previously set low limit value is being respected Green display not below limit value Red display below limit value The low limit value is indicated as an interrupted red line in the thread force diagram point 2 Fig 3 08 11 OK NOK OK The number of good docu seams is indicated NOK The number of bad docu seams is indicated 12 Option exceedings The number of preset and executed stitches within the docu seam area falling outside the limit values for thread force is indicated in this panel extended tolerance range with F6 and F7 The bold red lines in thread force diagram point 2 Fig 3 08 show this extended tolerance range If only 1 stitch exceeds this extended tolerance range an error warning is indicated immediately 13 Input Esc The mode in which the program is currently operating is displayed here by pressing key Esc Red display input not active Green display input active Input keys F2 F8 are unlocked 14 Stitches The number of stitches in the docu and test seam area is displayed here 15 Closed loop controller The preset Setpoint of thread force is indicated in this panel in cN This is the real gained representative Actual value for the corresponding docu seam area If the system was configured as thread f
45. n 2 digits for the year 3 digits for the day of the year 4 digits for Docu seam number Number of labels 0 9 Gemini T 68 mm x 17 mm Label output Identification number in addition with barcode Definition A digits for customer input 2 digits for the year 3 digits for the day of the year A digits for Docu seam number 1 digit for cross check number Number of labels 0 9 O For this label it is possible to enter 3 rows of clear text which are not printed Il but are saved in the seam file Gemini T 110 mm x 45 mm The transverse label printout offers a better print quality Remark Change printer driver settings Label Height 45 0 select Portrait The field Label output offers 3 selections Text 3 rows for clear text 1 row for label name and seam number 1 row for date and time 1 row for identification number 2 digits for the year 3 digits for the day of the year 4 digits for the Docu seam number PFAFF Operation Text Identification Barcode 3 rows for clear text 1 row for label name and seam number 1 row for date and time 1 row for identification nr in barcode option cross check nr 1 row for identification nr in clear text The Identification nr is defined as follows 6 digits for customer specific input e g password 3 digits for the year 3 digits for the day of the year 4 digits for the Docu seam number 1 digit for the cross check nr option only in b
46. ndicated Next Ready to install Next file is installed Install OK Shut down PC Restart Shut down PC PFAFF Installation 2 03 NI DAQ Hardware Configuration Remove plug from the mains plug in Nl board connect the flat wire Connect plug to the mains Start the PC My Computer Control Panel Add New Hardware Add New Hardware Wizard Next Next Search for your New Hardware Yes Next Next Detection progress is running Next Hardwaretypes are listed Select Data Acquisition Devices Next Models are listed Select Next Resourcetype and Settings are listed Next Finish Shut down PC Start WINDOWS My Computer Control Panel System System Properties Select Device Manager Open Data Acquisition Devices Open NI board Nl board Properties Select Resources if necessary change settings and select new value 1 0 range 0260 027 F interrupt 05 DMA 03 OK close Shut Down WINDOWS Start PC Go to Start Programs National Instruments DAO NI DAO Configuration Utility Correct configuration is indicated Next Configuration OK File Save Exit Handling conflict warnings If there is an interrupt conflict a new interrupt number must be set by a jumper on the Nl board see User Manual Similar to this set the DMA channel see Lab PC User Manual page 2 6 and the I O range see User Manual d An indicated interrupt conflict leads to a failure during data aquisition and indication for exampl
47. ng data appear which can be handled here Input of clear text Three rows with approximately 40 characters each can be entered Activate the input field of the first row the cursor blinks Enter the text and press lt Return gt Enter the text for the second row and press lt Return gt Enter the text for the third row and press lt Enter gt Label output Different output options can be selected Click on the arrow symbol The menu opens Click on desired field Text Only clear text is printed Text Identification barcode Cleartext and Identification barcode is printed Text Part code in ID barcode Cleartext 10 digits for user specific input and Identification barcode is printed installed on the WINDOWS platform See Chapter 2 08 01 Gemini T Label D To use the barcode function the appropriate software Option must be Printer Number of labels The desired number of labels from 0 9 can be selected by clicking on the arrow symbol f the setting 0 is selected the information no printer existing appears To end data input click on key return to save all adjustments Label selection Il If there was a wrong label name selected by mistake enter EXIT to execute a new label selection PFAFF Operation 3 09 09 Summary of the label sizes and printer selection Gemini T 45 mm x 155 mm Label output Clear text 3 rows for customer data Label name
48. o identification number with seamfile The LED indicator Docu Seam Area shows Test Only in Test seam it is possible to enter values into panels F3 F8 Docu seam lt arrow keys gt This function can be activated when all necessary values have been entered The seam supervision is active in the docu seam function as soon as the docu seam area is reached during the sewing process There are no inputs F3 F8 possible 9 Stitch edit With this function it is possible to activate both monitoring the number of stitches calculation of the average stitch length and the stitch regulator position See Chapter 3 09 04 Monitoring the number of stitches and 3 09 05 Monitoring the stitch regulator position 10 Label Scan By using this function information concerning the selected label can be entered See Chapter 3 09 07 Label name label selection In addition you can call up or execute the input for the scan function see Chapter 3 09 13 Scanner function 11 Label Form With this function the label size and label printer can be selected 12 14 Selection of measuring ranges Scale The measuring ranges for thread force and time axes can be selected using this function For the thread force full scale values ranging between 100 250 500 750 1 000 1 250 and 1 500 cN may be selected see Pos 13 on Fig 3 06 For the time axis you have the full scale values of 100 200 400 600 800 1 000 or 1 200 ms at your disposal see Pos
49. orce controller without feedback the indicator only shows the preset percentage value of thread force If there is a mechanic thread force adjustment this panel remains empty The necessary configuration is described in chapter 2 10 06 16 Thread force table All individual stitches sewn during a test seam or a docu seam are displayed in this table with the accompanying thread force In this way a seam analysis related to specific stitches is made possible 17 Maximum thread force The maximum thread force occurring during a test seam or a docu seam is displayed here 18 Minimum thread force The minimum thread force occurring during a test seam or a docu seam is displayed here PFAFF Operation 19 u Out of the thread force values of table 16 the arithmetic average is calculated and indicated 20 s Out of the thread force values of table 16 the standard deviation is calculated and indicated 21 24 Diagnosis LEDs To indicate controller signals and processes by using a simple method several diagnosis LEDs were placed in the lower right corner of the Docu screen WD Watch Dog blinks Program runs in Docu seam BT Bobbin Thread red Alarm signal of bobbin thread monitor Cut Cut red Thread cutting Stop Stop red Machine stops Error 9 25 Bar display bar graph When the static thread force is measured as well as during the test seam and the docu seam the value of the thread force that
50. ork driver for example select disk Diskdrive default A confirm with OK select Model of network card for example select SN 2000 Ethernet Adapter OK Definition Network protocol Network Add Protocol Add Manufacturer Microsoft Network protocol IPX SPX compatible protocol Release resources disk drive C of PC2 server Network Add Service Add Click File and Print Sharing for Microsoft Networks OK Click Network File and Print Sharing Mark both fields OK Select Network Access control with Share level OK Select work groups and PC identification For PC1 Network Identification input of PC name PC Work group Docu System Comment OK Same input for PC2 Restart the PC Release drives and folders on PC2 My Computer select drive C open with right mouse click the context menu click Sharing Sharing As Share Name C Access Type Read Write Access Apply OK PFAFF Installation 2 10 2 10 01 2 10 02 Example Open Network Neighbourhood after Network Installation click PC2 drive C open with right mouse click the context menu New Folder New Folder Rename PC1 input After clicking on folder PC1 the complete address is displayed in the task bar PC2 C PC1 Configure in PC 1 setup open DS Setup password 1 or 2 input In Setup level 2 input of path for seam files PC2 C PC1 then return to WINDOWS f both PCs are connected to a network seam
51. out of bobbin thread Thread tension is no longer adjusted manually but it is preset by an electrical actuator setpoint The closed loop controller always corrects the thread tension feed back In addition the docu seam system offers the possibility of continuing to process the data provided with standard spreadsheet programs A function for monitoring the number of stitches in the docu seam area calculation of the average stitch length can also be activated In conjunction with a PFAFF 3715 2 it is possible to monitor the stitch length setting dial determination of the stitch regulator position To increase process security 3 password levels are integrated which permit access on the system and user funcitons Using a scanner data comparison of the sewing process components is possible Sewing process data are saved under a significant identification number printout also on label or can be used for anetwork connection Recommendation in Docu Seam Area machine speed should not exceed 2000 min PFAFF 3 1 Operation 3 02 Password Input Setup levels The Docu Seam System is protected by 3 setup levels To configure these levels you have to run the program DS Setup started from the WINDOWS platform Setup level 1 gives the information to make a password input Fig 3 01 PFAFF Docu Seam System Fig 3 01 Starting up the system for the first time enter the factory preset password PFAFF Setup level
52. r PFAFF 3715 2 679 Error 92 restart of machine only by switching the main switch on off ll Error 9 machine stops Docu PC resets Error 9 then the machine can start again 727 Machine stops when residual amount of thread is reached II No machine stop when residual amount of thread is reached 4 01 01 Unlocking with password 1 or 2 If the process Change Bobbin Thread must be secured even stronger the machine release can be made by entering password 1 or 2 Therefore start program DS Setup and open the Functions to set the slider BT Change to Red After leaving the program DS Setup and starting the Docu Seam Program an additional input field for password 1 or 2 appears on the Docu screen After entering the correct password the sewing machine is unlocked PFAFF 4 1 Extension 4 02 Exit function for label 110 x 45 mm Using this integrated function you can react quick and flexible on changes in the production process If the label name process name exists in a printed barcode you can read this name immediately by scanner without opening the label file Advantage Using this method label data process data are downloaded automatically after scanning and also jumping back to the main program is executed at once This function too can be secured by password and switch Scan Exit in program DS Setup and Functions Green Execute Exit without password 1 or 2 Red Execute Exit with password 1 or 2 4 2 PFAFF
53. rimmer at the end of the seam area 3 J CE nodgeouog0 liz e oor SS LI Fig 3 38 Call up the function stitch length Number key 4 Enter value for the stitch lengths Confirm input with Enter key Call up the function for end of seam area Number key 9 If the stitch counter function is not switched on switch on the function Number key 1 Select the stitch counter function once again to open up the menue for input Enter number of stitches Confirm number of stitches with Enter key Switch on the Trim thread function Number key 5 Oo WEI S fe gt Clear EAEE _ Fig 3 39 Enter Press Enter key to teach in the end of the seam area WI Call up the End of program function PFAFF Operation 3 13 02 22 TEE Ce Fig 3 40 Enter Press Enter key to save the seam programm General information on seam programming on the PFAFF 3715 1 To achieve the best possible seam quality please observe the following information aOBEE As the thread force values are dependent on the speed it is useful to avoid changes in speed within the docu seam area This enables a better tolerance for the limit values and the number of seams classified as good increases The speed should be reduced 5 stitches before the docu seam area If a docu seam is classified as poor the sewing procedure can be ended or interrupted b
54. seam ara Red display not in docu seam area If F2 is on Test seam Test is written into this field 5 Docu seam The result of the Docu seam is displayed Green display docu seam is in order Red display docu seam is not in order Contemporary a numeric indication of the total number of executed docu seams is indicated indicator 11 Fig 3 8 indicates the OK and NOK docu seams 6 Skip stitches From this display you can recognize whether skip stitches have appeared in the docu seam area Green display no skip stitch Red display skip stitch 7 Stitch length From this display you can recognize whether the calculated stitch length in the docu seam area is correct preset seam length counted stitches Green display stitch length in order Red display stitch length not in order 8 Stitch regulator This display shows whether the preset position of the stitch regulator has maintained Green display position in order Red display position not in order 9 High limit value In this panel the adjusted value for the high limit value is displayed This display serves as an adjustment aid to recognize during a test seam whether the previously set high limit value is being complied with Green display limit value not exceeded Red display limit value exceeded The high limit value is indicated as an interrupted red line in the thread force diagram point 2 Fig 3 08 PFAFF Operatio
55. seam area P on2 Program 2 selected D on3 Switching program 2 to program 3 A on 1500 Speed 1500 min GG oni Select seam section 1 L on 20 Enter 20 as number of stitches Press F5 LED on call up second level of the F keys Press F1 LED on docu seam area activated Press F5 F5 blinks F1 LED off i e machine stops Press T12 LED on lift foot S on2 Select seam section 2 GL ont Program 2 finished move to program 3 S on0 Program combination L on 1 PFAFF 3 45 Operation Programming after the docu seam area P on3 Program 3 selected D on1 Return to program 1 A on 2000 Speed 2000 min S on1 Select seam section 1 L on 20 Enter 20 as number of stitches Press T14 LED on trim thread Press T13 LED on lift foot end of seam S on2 Select seam section 2 L on 0 Program 3 finished move to program 1 S on0 Program combination L on 1 Return to program start at No 1 by pressing P key If seams with more than 255 stitches are to be programmed the appropriate number of seam sections have to be selected For docu seams with more than I 255 stitches each additional seam section must be entered with the key sequence F5 F1 F5 docu seam activated 3 13 04 General information on seam programming on the PFAFF 3715 2 To achieve the best possible seam quality please observe the following information As the thread force v
56. settings To sew a docu seam configuration must be set to 10 For PFAFF 3715 2 using the machine panel parameter 683 must be set to Il if the selection slider is not positioned on Docu seam see chapter 2 10 05 Parameter Con figuration settings To sew a docu seam parameter 683 must be set to I 8 Selection F2 If the options display has been activated with F2 the functions can be selected by using the mouse or the arrow keys on the keyboard Thread force lt arrow keys gt By using this function the static thread force of both the needle and bobbin threads can be measured See Chapter 3 08 Measurement of static thread force Monitor lt arrow keys gt With this function the flow of the dynamic thread force during the sewing process is displayed on the thread force monitor This function may be employed for the analysis of signals and gives indications of the quality of stitch formation With a corresponding setting of the measuring ranges for the x and y axes detailed and characteristic features of the flow of the thread force can be recognized Save lt arrow keys gt Switching from Monitor to Save the dynamic thread force signal is saved on the screen PFAFF Operation Test seam lt arrow keys gt After calling this function a test seam simulated docu seam can be sewn with the slowest and fastest speeds planned for the docu seam area to check all settings There is no label printout and n
57. te time label format label name process name clear text number of labels high low limit values stitch length calculated seam length setpoint of no of stitches actual no of stitches no of stitches setpoint of stitch regulator position actual stitch regulator position tolerance option input actual option setpoint of thread force actual thread force value scan data Statistical calculation Min Max arithmetic average standard deviation thread force values for all stitches The thread force values out of the seam files can be processed further with standard WINDOWS spreadsheet software for example to prepare digrams or statistics PFAFF Operation 3 12 05 3 12 06 Saving seam files The default setting is to save seam files on hard disk under C PFAFF seamfile configuration in setup level 2 chapter 3 02 Data can be saved on floppy disk too configuration in setup level 2 chapter 3 04 Network saving configuration chapter 2 09 and 3 02 The stored seam files can be deleted or further processed in WINDOWS path C PFAFF seamfile It is recommended that the user should archive the stored seam files at time intervals determined by himself and then delete the archived seam files on the hard disk Seam file counter Under C PFAFF Counter sc txt 4 rows of information is saved gt Day of the year Counter for all docu seams Counter for
58. termining limit values nnennnnnnnnnnennnnnnenenennneneennenennnnnennnnn 3 18 3 09 02 Setting limit values nnnnennnnnnnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnennnnnennnnenennnnnn 3 19 3 09 03 Checking Bleu GE 3 20 3 09 04 Monitoring the number of stitches calculated stitch leng 3 21 3 09 05 Monitoring the stitch regulator position 3 22 3 09 06 Label sizes printer selection nee 3 24 3 09 07 Label namie label sel amp cti n a nsseieenee han 3 25 3 09 08 Text input for label Printer nennen 3 25 3 09 09 Summary of the label sizes and printer selection cece cccceeeeeceeeeeeeeeeeeecesetssaeeeess 3 27 3 09 10 Making Label Copies 0 ccccccccccscccccssessscstsesesssesseesestseessustcsstsessisecsstesaectscsesesnectecaes 3 30 3 09 11 Loading a label name from external device ccceeeccceccesseeeeeeeeecssseeeeeeescuaeeeeseeeeaaees 3 30 3 09 12 Information for ordering the required materials esennenenennneen 3 30 3 09 13 Scanner MUM sense rnit een 3 31 3 10 Detecting the Docu Zeam Area reter tr EAEE EEEEEEEEEEEEEEEEEEEEEEEE EEE EEE EEEE 3 33 3 11 Sewing with the Docu Seam System uussssnsunsnnnnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnennnnn 3 34 3 12 Output functions of the Docu Seam System ananeennnanneneennnnennennnnnnnn 3 35 3 12 01 Thread ioree diagfam nu ee 3 35 3 12 02 EE 3 36 3 12 03 Thread Kr 3 36 3 12 04 C ntents ofthe seam fil Stoeien n innen 3 36 3 12 05 Saving seam
59. the docu seam area is displayed in panel 7 Thread force table 8 contains all the individual stitches with the corresponding thread force values Maximum minimum of occuring thread force is displayed in panel 9 PFAFF Operation 3 12 3 12 01 The arithmetic average u and the standard deviation s are displayed in panel 10 Seam file is stored on the hard disk and or on floppy disk or linked to a network The appropriate label is printed Docu seam is not in order Display panel 2 and in case diplay panels 3 4 or 5 are red PC interface receives no signal Docu seam number is given The Docu seam NOK indicator in panel 6 is increased by 1 Total number of stitches in the docu seam area is displayed in panel 7 Thread force table 8 contains all the individual stitches with the corresponding thread force values Maximum minimum of occuring thread force is displayed in panel 9 The arithmetic average u and the standard deviation s are displayed in panel 10 Seam file is stored with the extension NOK on hard disk and or floppy disk or linked to a network No label is printed The LED indicators are reset automatically after thread cut Password after NOK seam To increase process security after a NOK seam you can finish the running sewing process only after entering password 1 or 2 Therefore start program DS Setup and open the Functions to set the corresponding slider Unlock Machine to Red After a detect
60. uld be reduced to 1500 min sos a SEER T em Fig 3 32 and the seam area should be recorded Alle Call up the function stitch length PR wt VALID 0 8 MM See DIFF 1 MM i Jelse L ee Fig 3 33 le Enter value for the stitch lengths Enter Confirm input with Enter key Wee EECHER lebt ce Fig 3 34 NO OF STITCHES 0 Call up the function for end of seam area Number key 9 WEEE aaron DS JAS ee Fig 3 35 Iess Call up the menu for entering the number of stitches Number key 1 PFAFF 3 41 Operation SES yH eee 5 C allelei Enter Fig 3 36 2 Enter desired number of stitches Enter Confirm number of stitches with Enter key Switch on the function Docu seam area Switch on the function Stop d Esc CECR m Bade ls lelelzlsllsle Enter Fig 3 37 Enter Press Enter key to teach in the end of the seam area elek Enter desired speed Enter Confirm speed with Enter key Press Enter key to teach in the second seam area Enter The computer jumps to the input for the third seam area Operation Program the third seam area docu seam area The seam area should have a stitch count function 20 stitches a stitch length of 2 5 mm for roller presser and feed wheel and a thread t
61. up Parameter Meaning Adjustm range Standard setting 205 Max speed in Docu Seam Area 100 2000 1500 221 Max speed for sewing program 300 6400 3200 607 Max speed 100 10 000 3200 683 A Ei Docu seam monitoring yes no yes selection slider F2 must be positioned on Docu seam If these conditions are not fullfilled a watchdog function is blocking the machine a sewing operation is not possible II no selection slider F2 must be positioned on Test seam Save Monitor or Thread force The machine can be used completely independent on the Docu Seam System 991 WINDOWS M default 0 239 217 992 WINDOWS K default 0 239 85 Because of process security watch the parameter 683 and Configuration 9 or 10 For information please see instruction manual of motor manufacturer PFAFF Installation 2 10 06 2 11 Adjustment of thread force thread tension The configuration must be executed in file Pfaff DS INI txt The first character in this file defines the wanted version O without electrical adjustment mechanical version 1 electrical actuator for adjustment 2 electrical actuator for automatic controller closed loop adjustment i The exact function of setting controlling the thread force is described in chapter 3 06 point 6 Scanner Installation Looping the scanner vi
62. which password number the hidden password 3 has started the system PFAFF Docu Seam System Input of max letters Fig 3 05 Path for seam files Enter the path for saving seam files in Setup level 2 Fig 3 02 If no path is entered seam files are saved automatically under C PFAFF Seamfile see also chapter 2 09 02 Configuration principle Saving docu seam files on floppy disk too If docu seam files have to be saved not only on hard disk or network but also on a floppy disk this function can be released or deactivated see chapter 3 05 Move the function slider to green an input field in setup level 2 is indicated Fig 3 02 to enter the path folder for seam files also on floppy disk The path A Seamfile is preset automatically may be changed if necessary The existing saving procedure on hard disk or network remains independent on this action If no floppy disk was inserted an indication appears on the screen Please insert floppy disk Data were already saved on hard disk or network If a read only floppy disk was inserted an indication appears on the screen Remove read only on floppy disk e g set startup in BIOS on C In case of inserting a floppy disk without path folder the preselected path in setup program is activated PFAFF Operation 3 05 If memory capacity on the floppy disk is filled up to 1 38 MB an indication appears on the screen Floppy disk full insert new f
63. y switching over to manual sewing To quit the error indication and to be able to sew manually the Number key 1 must be operated If the sewing procedure is to be started at certain seam sections the sewing positions and program positions must coincide If necessary the program must be set at the required starting point manually The needle must be positioned within the fabric at end of Docu seam and stop within Docu seam to prevent slippage or withdrawal of fabric Additional symbols on the control panel Docu seam area activated Bad NOK Docu seam Good OK Docu seam No Watchdog function machine PC communication is interrupted machine stops PFAFF Operation 3 13 03 PFAFF 3715 2 VA CH ETTERNT EEE B DI P S L 0 A l O O O O O O F O A O O AN a Leela Fig 3 41 T9 T12 Tis T14 Programming before the docu seam area Switch on mains switch Key T9 on PM LED is on P on1 Program start on program number 1 D on2 Switching program 1 to program 2 A on 2000 Speed 2000 min S on1 Select seam section 1 L on 20 Enter 20 as number of stitches Press F1 LED on i e forward to next program without a stop S on2 Select seam section 2 L onO Program 1 finished move to program 2 S on0 Program combination L on 1 Programming in the docu

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