Lingchen Technology PLC Overlock Machine Solution

In the textile industry, towel overlocking machines have long faced a critical challenge: the need for manual calculation of trajectory interpolation coordinates for complex patterns. Under traditional G-code interpolation schemes, operators are required to manually calculate the coordinates for every interpolation point based on the pattern graphic—a process that is tedious, time-consuming, and prone to error. Furthermore, changing patterns or dimensions necessitates a complete recalibration, placing extremely high demands on the operator's professional expertise. Drawing upon over two decades of accumulated expertise in motion control technology, Lingchen Technology has successfully developed a new type of overlocking machine—centered around its proprietary industrial PLC—that features "one-click pattern import for complex designs." By employing inverse kinematics trajectory algorithms to automatically calculate interpolation coordinates, the machine achieves highly simplified operation and robust pattern compatibility, thereby completely eliminating the cumbersome manual process of calculating interpolation trajectories.

Key Process Points and Performance Indicators

Process Logic
Multi-axis Coordination: Synchronized operation of the sewing machine axis and the trajectory axis.
Critical Alignment: Precise matching of the sewing machine stitch pitch with the trajectory step length (Core Quality Assurance).
Action Synchronization: Synchronized control across the entire workflow—feeding, sewing, cutting, and material collection.

Performance Specifications
Linear Speed: 150 mm/s
Arc Speed: 50 mm/s
Thread Feeding Speed: 100 mm/s
Slow Start Speed: 10 mm/s
Slow Start Stitch Count: 1–3 stitches (Configurable)
Stitch Length: Configurable
Reinforcement Stitch Length: Configurable
Core Function: One-Touch Pattern Import

Key Technical Challenges:
Automated G-code generation from graphic data → Inverse kinematics coordinate transformation → Servo interpolation and positioning. Core challenge for multi-pattern compatibility: precisely matching stitch pitch with trajectory step length to prevent fabric puckering and thread tension issues, thereby ensuring optimal sewing quality.

Customer Pain Points

❌ No Visual Guidance: Traditional CNC interpolation calculations are cumbersome and inefficient.
❌ Complex Debugging: Changing patterns or dimensions requires extensive debugging and is time-consuming.
❌ High Barrier to Entry: The multitude of parameters demands a high level of professional expertise from operators.
❌ Precision Unreliable: Manual calculations are prone to error, resulting in low overlocking precision and poor product consistency.

Lingchen Technology Solutions

The integrated hardware and software solution—comprising the Lingchen PLC1000 series, Lingchen servo drives, and Lingchen touchscreens—has successfully met all performance benchmarks, including a linear speed of 150 mm/s and an arc speed of 50 mm/s. The system operates with exceptional stability and zero step loss; sewing is free from puckering or tension-related distortion, while overlocking precision and product consistency have been significantly enhanced.

Core Functional Modules

① The One-Touch Import Module supports the direct import of DXF/CAD graphics, featuring automated parsing that eliminates the need for manual programming.
② A proprietary inverse kinematics algorithm powers the LCT_TRAOF_XYR inverse kinematics function block, enabling automatic coordinate calculation and the precise generation of interpolation trajectories.
③ The multi-axis servo linkage architecture is built upon an EtherCAT-based multi-axis servo system, ensuring a precise match between stitch pitch and trajectory step length—thereby fundamentally resolving issues related to fabric puckering.
④ A streamlined Human-Machine Interface (HMI) design features an intuitive touchscreen, offering parameter visualization and "foolproof" operation that allows even operators with zero prior experience to quickly master the system.

Value and Advantages

① One-touch pattern import enables operators with zero prior experience to get started immediately; a proprietary algorithm eliminates manual errors; versatile compatibility supports rapid pattern switching across multiple graphic formats; and multi-axis linkage fundamentally resolves the industry-wide pain point of fabric puckering. Furthermore, a complete suite of proprietary hardware and software ensures convenient maintenance and controllable costs.
② This system lowers operational barriers and labor costs, boosts the efficiency of pattern changes and equipment utilization, guarantees the quality standards required for high-end textiles, and enhances the capacity to rapidly respond to diverse production demands.

Empowering Intelligent Textile Manufacturing Through Technological Innovation

From manual point calculation to one-touch pattern loading, and from complex commissioning to ultra-simple operation, Lingchen Technology has completely revolutionized the user experience of towel overlocking machines through a comprehensive solution integrating PLCs, servo drives, and touchscreens. This represents far more than a mere equipment upgrade; it signifies a paradigm shift in production processes. We firmly believe that Lingchen’s solutions—anchored by industrial PLCs, driven by proprietary algorithms, and underpinned by seamless hardware-software integration—will continue to inject new momentum for intelligent manufacturing across industries such as textiles, 3C electronics, semiconductors, and new energy.

About Us

Established in 2006, Suzhou Lingchen Data Acquisition & Computer Co., Ltd. operates under a business philosophy centered on creating value for clients and fostering win-win partnerships. The company provides customers with core components and system solutions for a wide range of automation equipment, including industrial computers, motion control systems, test and measurement instruments, machine vision systems, and robotics. Currently, Lingchen oversees two wholly-owned subsidiaries: Suzhou Xun'ya Automation Technology Co., Ltd. and T.O.K. Robotics (Suzhou) Co., Ltd., which specialize in the sales of robotic systems and the R&D, manufacturing, and sales of linear motion products, respectively.

Product System Network

Within the hierarchical structure of automated control networks, Lingchen Technology offers a comprehensive range of products spanning the device, control, and information layers.

01  Industrial Computers

Lingchen Industrial Chassis provides comprehensive physical protection for critical computing cores through its industrial-grade robust structure, exceptional thermal management, and dust-proof design, ensuring enduring and stable operation even in harsh industrial environments characterized by vibration, dust, and extreme temperatures.

02 Embedded Industrial PC

Lingchen Embedded Industrial PCs feature a compact and rugged industrial design, integrating high-performance computing, extensive I/O interfaces, and broad tolerance for wide temperature and voltage ranges. Specifically engineered for embedded applications—such as machine vision, edge computing, and automation equipment—these systems provide a stable and reliable intelligent core within limited spaces, empowering smart manufacturing and IoT applications.

03 Motion Control Card

The Lingchen motion control card is capable of controlling up to 32 motion axes and simultaneously supports the control of up to 512 DI points and 512 DO points, with a maximum bus communication cycle of 250 µs. In terms of motion control, it supports functions such as single-axis relative motion, absolute motion, jogging, and drive-based homing; multi-axis interpolation; multi-axis point table motion; and electronic gearing.

04 LMC Series Motion Controllers

The Lingchen LMC series motion controllers are designed around an open, hard real-time kernel (with jitter < ±0.3 µs). This design thoroughly resolves the non-real-time limitations inherent in traditional Windows-based platforms, ensuring both determinism and instantaneous response for multi-axis commands. Installation is remarkably simple, requiring only a single Ethernet cable for connection; furthermore, utilizing highly efficient asynchronous communication technology, the system enables the synchronized issuance and control of motion commands for up to 12 axes within just 1 millisecond.

05 NAC Series High-Performance Motion Controllers

At the core of the Lingchen NAC controller lies a powerful bus expansion capability, supporting four EtherCAT masters to enable the precise control of 256 axes per station—totaling 4,096 I/O channels. Its motion control capabilities are both comprehensive and robust: beyond standard point-to-point, linear, and circular interpolation, it features advanced functions such as 5-axis interpolation, spline-based trajectory smoothing, and dynamic coordinate systems. Furthermore, it integrates vibration suppression, "soft landing" capabilities, and high-precision position comparison outputs; combined with eight independent interpolation groups and continuous interpolation functionality, it effectively meets the demands of complex trajectories and high-speed synchronization. The development environment is open and flexible, supporting multiple programming languages—including C++, C#, and Python—and allows for direct programming within the real-time operating system, thereby significantly enhancing integration and debugging efficiency.

06 PLC Motion Controller

Lingchen PLC controllers strictly adhere to PLCopen specifications and the IEC 61131-3 international standard, combining high performance, a compact footprint, and a modular design to facilitate easy development and flexible deployment. Widely applicable to automation equipment and production line systems across sectors such as 3C electronics, lithium-ion batteries, packaging, and printing, these controllers can also be extended to serve as network communication nodes within integrated production lines for logistics, automotive, and consumer goods industries. By meeting requirements for internal/external network isolation, high-speed bus communication, and real-time data processing, they provide a stable and reliable control core for a diverse range of industrial environments.

07 Industrial Network Cards

Lingchen industrial network cards are specifically engineered for harsh industrial environments, featuring 10/100/1000Mbps auto-negotiation capabilities to deliver stable and reliable high-speed network connectivity. Characterized by robust anti-interference, surge protection, and wide-temperature operation, these cards are widely deployed in critical applications such as motion control, machine vision, and automation systems. The products feature a flexible installation design—including a standard full-height bracket and an optional half-height bracket—enabling seamless integration into a wide range of smart manufacturing equipment and industrial networks.

08 IO Module

Lingchen Technology offers a comprehensive range of I/O module solutions, designed to meet the diverse requirements of industrial automation flexibly.

LC/LD Series Expandable I/O Modules: Supporting multiple protocols—including EtherCAT, Profinet, Ethernet/IP, and Modbus TCP—these modules allow for the flexible expansion of data acquisition capabilities covering digital signals, analog signals, temperature, pressure, and pulses. They are widely applied across sectors such as 3C electronics, lithium-ion batteries, semiconductors, automotive manufacturing, and medical equipment.

MINI Series I/O Modules: Characterized by their compact size and high real-time performance, this series encompasses digital I/O, analog I/O, temperature modules, and communication modules. They are ideally suited for control and data acquisition scenarios where space constraints and real-time responsiveness are critical requirements.

GWS Series Cabinet-Free I/O Modules: Featuring exceptional stability and convenient network cabling capabilities, these modules are designed for distributed system layouts, enabling significant reductions in both system integration time and costs.

Our entire product portfolio is dedicated to providing users with reliable, easy-to-integrate, and adaptable I/O module support for a wide variety of application scenarios.