FATEK Automation Corporation

With the continuous development of global industries such as textiles, apparel, home goods, luggage, and footwear, the industrial sewing machine market is undergoing a new wave of transformation and upgrading. Against the backdrop of rising labor costs and increasing demand for personalized customization, traditional sewing equipment can no longer meet modern manufacturing's requirements for efficiency, precision, and intelligence. The market is now showing a clear trend toward automation, with servo drive technology, IoT integration, and smart-assist functions gradually becoming industry standards.

From a market demand perspective, garment manufacturers are actively seeking automation solutions to reduce reliance on labor, while small-batch, high-variety production models place higher demands on equipment flexibility. Brands' strict quality control further drives the need for high-precision, high-stability equipment. On the technical front, servo control systems significantly improve energy efficiency and sewing accuracy, while IoT applications enable remote monitoring and smart maintenance—innovations that are reshaping the industry landscape.

In terms of policy environment, national smart manufacturing strategies provide strong support for high-end sewing equipment R&D, and well-developed industrial clusters in regions like the Yangtze River Delta and Pearl River Delta create favorable conditions for technological innovation. Meanwhile, the industrialization of emerging markets such as Southeast Asia and Africa presents new growth opportunities for domestic equipment exports. Against this backdrop, this project targets the mid-to-high-end market, focusing on breakthroughs in specialized sewing equipment development. By integrating advanced servo control technology and smart human-machine interfaces, we aim to build a competitive product lineup while establishing a digital service platform to provide customers with comprehensive smart sewing solutions.

This solution adopts the FATEK P5 series 7-inch touchscreen as the human-machine interface (HMI), paired with the FATEK M series MQ2M3-1616T 4-axis pulse output control host to form the core control system. The system utilizes two FATEK SC3E servo drives to achieve precise motion control, along with an analog input module for real-time monitoring of the relative distance between the workpiece and needle, forming a complete closed-loop control.

The system features a modular design architecture, where the main controller ensures sewing position accuracy of ±0.01mm through high-speed pulse output to precisely control servo motor operation. The analog module collects distance signals in real time at 16-bit resolution with a sampling rate of 1kHz, enabling dynamic compensation adjustments via dedicated algorithms. The touchscreen interface integrates parameter settings, process recipes, fault diagnosis, and supports bilingual (Chinese/English) switching, with an operational response time of less than 200ms.

The servo system employs a full closed-loop control strategy, combined with proprietary anti-interference algorithms, maintaining stable operation even under high-speed sewing conditions (up to 5000rpm). The system includes an automatic calibration function for one-click mechanical origin alignment, significantly reducing equipment setup time. Data exchange between modules is achieved via EtherCAT bus, ensuring control command transmission latency below 1ms. Additionally, the system incorporates multiple safety protection mechanisms, including overcurrent, overvoltage, and wire-break detection, ensuring reliable operation.

► Efficient Production, Increased Capacity
Automated Continuous Operation: Pre-set multiple sewing programs for unattended continuous production, with maximum sewing speed up to 5000rpm, improving production efficiency by over 40%.

Quick Changeover: Switch process recipes with one touch on the HMI to adapt to different fabrics and stitch requirements, minimizing downtime and enabling flexible small-batch, high-variety production.

► Precise Control, Quality Assurance
High-Response Servo Drive: Equipped with FATEK SC3E servo system and 4-axis pulse control, achieving positioning accuracy of ±0.01mm for uniform and neat stitches.

Smart PID Adjustment: Real-time monitoring of needle-to-workpiece distance (analog signal) with dynamic feed speed adjustment, keeping seam margin error within ±0.1mm to prevent skipped stitches and thread breaks.

► Reliable Operation, Reduced Maintenance
Industrial-Grade Hardware: FATEK MQ2M3-1616T PLC features strong EMI resistance for stable operation in complex workshop environments, with MTBF exceeding 10,000 hours.

Smart Alerts: The system monitors motor load and needle position, automatically stopping and pinpointing faults when anomalies occur, reducing equipment damage risks and cutting maintenance costs by 30%.

► Energy & Labor Savings, Lower Costs
Servo Energy-Saving Technology: 25% lower energy consumption compared to traditional clutch motors, delivering significant long-term electricity savings.

One Operator, Multiple Machines: High automation allows a single worker to handle loading/unloading only, reducing labor needs by 50%—ideal for labor-strained manufacturers.