High-speed processes such as digital printing, finishing, and cutting require precise, real-time detection and control of the material web. Conventional sensor systems often reach their limits in these applications due to complex patterns, materials, or edge structures. AI-based optical sensors bridge this gap by interpreting visual data and deriving the necessary parameters for process control. In this context, ELSEAMTEX and ELWARP from Erhardt+Leimer offer innovative solutions.
ELSEAMTEX
The ELSEAMTEX SI 1001 seam sensor is an optical inspection system designed for the non-contact detection of seams on textile webs. By utilizing AI, the system can detect cross-seams on both solid-color and printed materials. ELSEAMTEX combines a ring-shaped light source with a matrix camera and integrated data processing capabilities. The AI-based software analyzes the captured image data to identify complex seam structures. Additionally, the sensor generates a digital signal that is integrated into the machine control system upon seam detection. This allows for automated actions such as opening calender rolls, lifting shear cutters, or pausing printing processes in digital printing machines. At the same time, the signal output facilitates the processing of production data. Another feature of the ELSEAMTEX system is its integrated Wi-Fi module, which enables wireless communication with mobile devices. Using the “E+L AI Manager” app, users can perform software updates, test them in real-time, and retrieve log files.
ELWARP
The ELWARP SI 2001 warp thread sensor is designed to detect the outermost warp thread. Conventional systems often rely on the position of protruding weft threads and can only infer the cut edge indirectly; in contrast, ELWARP focuses directly on the relevant warp thread, enabling control of downstream processes. The system combines incident and transmitted light methods with AI. A matrix camera captures the material edge, while an additional light source generates contrast and makes the thread structure visible. Artificial intelligence analyzes the data to identify the outermost warp thread, regardless of the length or irregularity of the protruding weft threads. The determined warp thread position is transmitted to control systems, allowing for the implementation of knife-tracking mechanisms at the stenter exit. Furthermore, ELWARP enables precise control based on actual material structures. ELWARP is also equipped with a Wi-Fi card and can be operated via the “E+L AI Manager” app.
Digital Printing and ELWARP
In digital printing, it is crucial that no weft thread protrudes from the textile structure; if a thread caught by the print head damages the textile surface or the print head itself, the consequences are costly. The ELWARP sensor camera from Erhardt+Leimer detects the outermost warp thread and aligns the cutting knife accordingly.
Erhardt+Leimer
Erhardt+Leimer is an internationally oriented corporate group headquartered in Augsburg, specializing in the development, manufacture, sales, and servicing of products for the automation and inspection of moving webs and belts. Founded in 1919, the company currently employs 1,600 people at 18 international locations worldwide.
