[amayausers] Re: Unsolved thread breakage problem

Dear Amaya Group:
I've watched this list since before we purchased our new Amayas, and was 
helped with my decision to get the Amaya based on a phone conversation with 
Aaron. 
 I've been involved with embroidery and digitizing since mid 1995 and 
consider myself very mechanically inclined. Two things made us finally make the 
plunge into the Amaya technology, one is Melco's investment in a new concept 
for 
thread tensioning and the speeds that Amaya can obtain. We have a Barudan 
machine that at best we can run at 500 spm, although it produces beautiful 
embroidery at that speed or less, thread tensioning is a constant problem among 
other 
things. So far I haven't seen any other machine manufacturers attempt to 
improve the thread tensioning mechanism with any new approach except for Melco.

That said, along with any new technology there exists a learning curve and 
perseverance to make the new ideas work on both the part of the vendor as well 
as the users of the new technology. I get really concerned when I hear about 
thread breaks and the frustration that goes along with the territory. I have 
had 
a number of problems with thread breaks all of which have been resolved for 
the most part, and all of which would not be resolved if I gave up and tossed 
out the new technology and went back to 500 spm.

The things that can go wrong seem to be fairly logical and can be deduced by 
going through the machine's thread paths and making sure they are all working 
properly. First is the thread cone, is it good quality thread that comes off 
the cone smoothly? If the thread is wound the wrong way around, it will twist 
tighter and tighter as it goes through the thread path to the point where it 
breaks from the twist. Next comes the material feed roller.  In the software, 
if 
not enough material feed is given for a particular fabric, a grove can be 
produced into the rubber wear surface rather quickly. I have seen two different 
types of grooves, short ones about 1/4 inch long on several places around the 
rubber surface, or a single long one that goes all the way around the wheel. 
Either type of groove will catch the thread on occasion and cause it to break, 
and the wheel must be replaced. I think that the rubber surface is prone over 
time to wear, regardless of how well the material feed is set, however it can 
last way longer if these settings are correct. Next is the needle, of course 
there are a bunch of things that can go wrong with needles that can carve up 
thread, I sometimes check the needles through a magnifying glass for burrs 
etc., 
but needles must be replaced if there is anything wrong with them. Although 
the throat plate is the next concern, I realized that the Amaya's throat plate 
is much harder, and that the one on my Barudan machine I had to inspect and 
polish off burrs etc., on a regular basis.

Next is the hook assembly and bobbin combination. I started a new paragraph 
for this area because it has become a great deal of concern for me lately.  
I'll start with saying that there is no difference between the Amaya and any 
other machine on the market in the way the stitches are formed, and the hook 
and 
bobbin cases could probably be exchanged between many other makes of machines 
in operation today. I have come to realize that the hook timing and needle 
depth are very critical adjustments on the Amaya, and that the tolerance of 
these 
adjustments is less forgiving than on older slower machines. Also the distance 
between the hook tip and the needle scarf is very critical, and if not in 
tolerance will eat thread like there is no tomorrow. However, if all the 
mentioned adjustments are correct there may be full production runs with few or 
no 
thread breaks. In my opinion it is extremely important for anyone running any 
commercial embroidery machine to have enough understanding about these 
adjustments and/or tolerances to at least be able to figure if something is 
wrong with 
them. As for my recent concern over hook adjustments: I have gone through 
several hooks since I have my new machines, and I believe that the reason is 
simply 
that I don't think that the hook assemblies currently used in the Amaya are 
up to the speeds that the machine is capable of. I noticed that some of the 
hooks get sloppy after only a few days of operation even if oiled properly, or 
even more than is generally required. The reason for this could possibly be in 
the way the hook assembly is manufactured. It could be the way in which they 
are heat treated or chromed, or if they somehow got a burr or other 
contamination somewhere along the way.  When the hook is going bad, it has a 
distinct 
hollow sound as it is chewing up the thread, as if marbles were being shaken in 
a 
heavy can or tank. One can tell if the assembly is loose by taking the bobbin 
case out and jiggling the center post on the hook assembly, some play will 
always be there even on a new hook, but if it feels sloppy and can move in and 
out or side to side it could well be bad, and should be replaced. 
I understand that Melco is aware of this problem and that they are 
researching various hook designs, and I think they will make good on this 
issue. 
However, in the mean time I would be interested if other users have experienced 
this 
problem and what they have done for a remedy. Our technician replaced a hook 
on one of our machines last week and it diminished the thread breakage a great 
deal and the machine sounds very smooth now as it sews. I could have replaced 
the hook myself, but I decided that Melco needs to be more aware of this 
problem than simply sending me another hook under warranty. I think that, that 
was 
the fifth or sixth hook that has been replaced on our two machines in the last 
five months. I'm sorry that this is such a long e-mail but obviously I see 
this as very important to the success of the Amaya, and that I really want the 
Amaya to be a success.

Last but not least, thread breaks can be directly related to how a design is 
digitized. If a design is too dense and/or short stitches are too short thread 
breaks will occur. I never liked the way bean stitches sew on my Barudan 
machine and they seem to have the same problems on the Amaya. Other than that, 
I 
have found that using good digitizing techniques for underlay and fill or satin 
density's and stitch lengths will yield a design that sews without thread 
breaks. If one is determined that it is possible to never have any thread 
breaks 
while producing embroidery, it's time to look into some other type of 
business. But it is possible to bring thread breaks to a minimum by having a 
good 
handle on the machine/design basics.

If others have experienced similar problems with hook assembly issues, please 
share them with this group and your Melco representatives. 

Sincerely, 
Ward H. Wentzel
e-mail= santics@xxxxxxx
screen-antics.com

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