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KL 500

3D Robot sewing unit
Auto / CarArmaturenbrett / Dachboard

Sewing competence and unique expertise in handling & tooling are combined in the KSL’s KL 500 robot units for robot-supported production of application-specific decorative seams in the automotive interior sector. Integrated into complete 3D sewing cells, these robot units are used in automotive dashboard production plants (24/7 production) around the globe. With these systems, complete dashboards and other interior elements are stitched in a highly efficient, process-safe and repeatable way – with operator intervention reduced to a minimum. The KL 500 guarantees the highest quality with significantly minimized waste. The revolutionary, fully automatic seam path correction using Vision System for the correction of material-specific position deviations guarantees maximum reproducibility of the seams.


  • Fully automatic seam path correction via VISION SYSTEM, for correcting material variances in leather
  • Maximum reproducibility of the seams for highest demands on quality.
  • Industrial robot with additional, fully synchronous sewing axes
  • Robot sewing head: 1- or 2-needle double chain stitch column sewing end-effector
  • Individual sewing head design (clearance and height of column) for processing of most varied dash board geometries
  • Rotary indexing table for overlapped procedure and highly efficient cell utilization
  • Tool changer for fully automatic exchange of various sewing heads
  • 3D-component support for material specific, reproducible positioning of ambitious interior components


  • Seam beginning and –end in the component with positioning of the thread ends at the material underside for simple automated
  • seam securing without manual interference
  • Customer- or application specific design of the cell layout to achieve highest efficiency of the workflow
  • Linkage with leading and trailing manufacture processes
  • Integration of safety relevant quality monitoring systems, such as material recognition, color recognition, barcode recording
  • Barcorde printer
  • Thread breakage recognition, loading monitoring etc.
  • Linkage to customers PPS-System
  • Application specific thread cutters, depending on costumers demands
  • Integration of additional features into the component support
  • Automatic template recognition in the loading area as well as triggering of additional features
  • Automatic template transport systems
  • Automatic part withdrawal systems

It’s all about the right functional head for every customer application! 
With the KL 500 concept, the machine can be equipped with a range of different sewing heads or functional heads (Single- or double needle).

Here you can download a list with the existing heads:

Project example: Top-stitching dashboards of a european automotive company
The customer is a global tier 1 company, which produces for a well-known German car manufacturer. In fact, entire dashboards made from slush material are stitched with high efficiency, process reliability and repeatability. The unit includes robot, a Vision system, component holders, rotary indexing table, sewing heads (2-needle double chain stitch - special post), protective fence concept etc. Using the KL 500, various products can be manufactured with minimal conversion effort. The only things that need to be changed are the component holders and possibly the sewing head. Thus, the unit combines flexibility with the highest level of precision and productivity. The machine is deviced and realized as a „customer solution“ and subsequently implemented into the customer‘s manufacturing process READY FOR PRODUCTION.

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