In-line actuators for spreading machines Gerber Technology develops and manufactures spreading machines for the textile industry. They have gained competitive advantages through a development project on an existing machine. Individually controlled in-line actuators helped in achieving this result. At Gerber Technology, a division of Gerber Scientific in Denmark, there is comprehensive experience with the production of spreading machines and an ongoing product development has ensured the company a leading position on the market around the world. On an annual basis, the company produces almost 350 machines to continents all over the world. A good example of a successful development project at Gerber Technology is the extensive re-design of their large XLs125 spreading machine. A product committee comprising management, engineering, sales and service had defined the dimensions beforehand, which among other things, prescribed the integration of a completely new control, a more ergonomic design, a more solid construction and all of this at a considerably lower cost price. The comprehensive task was given to the development team under the manager for mechanical development, Kim Svane Brinch, who, in August 2006, initiated the project at the factory in Denmark. "To fulfil the goals from the product committee has meant that we have not focused on doing what we ‘usually’ do, but that our thoughts have been on new constructions and new components. In relation to the ‘old’ machine, we have made new developments on a number of areas, such as the cutting device and the construction and control of the cradle for the rolls of fabric", says Kim Svane Brinch. In order to ensure a very precise spread, the cradle is controlled by 3 individually controlled actuators. The old machine used traditional linear actuators, whilst the new machine is fitted with in-line actuators. This type of actuator, which is developed and produced by the Danish company concens is characterised by great strength in connection with the compact dimensions, a precise control and a solid and modern design. Therefore, they were the obvious choice for Gerber Technology for their spreading machine. "Experience has shown that actuators are exposed to great impact stress when the operators throw a heavy roll of fabric down into the cradle from a truck", tells Kim Svane Brinch. "At the same time, the old actuators were fitted with a motor on the side, which made it difficult to build them into a compact machine design". Since September 2007, when the first machine was put into operation, there are now more than 20 machines installed around the world and at Gerber Technology no problems have been experienced with concens' actuators as with earlier actuators. At the same time, the in-line actuators have contributed to the achievement of a very harmonic design of the machine, which gives a visually attractive machine and better ergonomics for the users. When fitting and service personnel are used to working with components for many years, misgivings often arise when you introduce new components that have to be fitted in a different way. "Our personnel were familiar with another type of actuator for many years and were used to fitting, replacing and programming them. When we presented concens’actuators to them, there was naturally some scepticism - not least because they are very small in dimension. But when they began using concens’ actuators, they could easily see the advantages and the great strength of in-line actuators", Kim Svane Brinch continues. At the same time, the development team worked consciously on easing the work processes in the new machine. For example, basically all screws in the entire machine are the same size and the construction of the computer and control box is completely changed. Where there was previously an assembly time of 2-3 hours and approx. 400 screws, the new model can be assembled in 10 minutes. So also on that front there have been significant savings - and not least great satisfaction from the fitters and service personnel. "In the industry, we are considered as being almost the B&O of this type of machine - with regard to new technology, functionality and good design", says Kim Svane Brinch with a natural delight in his voice. "We are a young team of developers who have worked targeted and structured in improving all components and processes through time studies, cost reduction and ergonomics. So there is, of course, great satisfaction when we succeed. And at the same time, we have made a new, improved machine that provides considerable competitive advantages so that we, in the team, can look back on a machine we have made that lies under the product committee’s initial established cost price. This is the first time in Gerber Technology’s history that this has happened". Gerber Technology in Ikast produces 150 machines of the type XLs125 annually. In order to ensure a low cost price, there is great focus on the Chinese market in regard to components and manufacturing of the machine. Naturally, this has given the development team a further task as considerable demands are placed on a thorough documentation and not least, that all component suppliers need a Chinese distributor. "But that is also an important part of any development project to keep in mind; that component suppliers today must be international," concludes Kim Svane Brinch. 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