A broken warp thread on a loom doesn't stop the loom — it ruins the next 50 meters of fabric until someone notices. Optical thread-break detection sees the break in under a second, halts the loom, logs the event, and lets the operator restart with minimal scrap.
Modern looms run at 600 picks per minute. A thread break that goes undetected for 30 seconds wastes more fabric than the inspection system costs to install. Photoelectric drop-wires miss thread-tension events; optical AI catches them before the next pick.
Drop-wires only catch a fully broken thread that drops below the wire. Tension events, slow breaks, and broken filament strands pass through undetected. We mount a line-scan camera over the warp sheet; the AI flags every visual anomaly in tension or coverage. Drop-wires stay as backup; the camera adds the optical layer.
The IX-LS/02 line-scan AI system is the right tool for this — 16,384 pixels across the warp, 80 kHz line rate, encoder-locked to the loom shaft. Defects mapped by warp position and pick number. Direct integration with Picanol, Toyota, and other major loom electronic boxes via Profinet or EtherNet/IP.
Continuous line scan across the entire warp at every shed change.
AI evaluates yarn-by-yarn coverage and tension uniformity. Anomaly flagged at sub-pick resolution.
Verdict to loom controller in <300 ms. Loom brakes within next pick.
Break event logged with timestamp, warp position, and image. Per-shift quality reports built automatically.
Tell us your line, your existing equipment, and your tolerance window. We'll come back with a retrofit assessment, a greenfield specification, and a rough cost estimate within two business days.