Sewing apparatus synchronization method and system

Abstract

The application discloses a sewing equipment synchronization method and system, comprising the following steps: obtaining process parameters of sewing equipment and habit parameters of operators; determining process scores according to the process parameters and the habit parameters, and sending production scheduling signals to hanging equipment according to the process scores; realizing automatic production scheduling, providing a process adjustment tool, so that process is automatically arranged, IE time is saved, full-process automatic optimization is realized, a plurality of sewing equipment are communicatively connected, the networking of each different sewing equipment is realized, and unified production scheduling of a plurality of different sewing equipment is realized; each dimension process data is monitored, employee skills are evaluated, and car workers are arranged work in a targeted manner, so that car worker productivity is improved.

Description

Technical Field

[0001] This invention relates to the field of collaborative control technology for sewing equipment, and in particular to a method and system for synchronizing sewing equipment. Background Technology

[0002] In existing technologies, the basic concept of garment hanging equipment in the apparel industry is to hang entire garment pieces on hangers and automatically deliver them to the next operator based on pre-inputted process segments, significantly reducing non-productive time such as handling, binding, and folding. After a production worker completes a process, they simply press a control button, and the hanging equipment automatically transfers the hanger to the next workstation and performs piecework calculations. Garment hanging systems can handle garment production scheduling, effectively controlling garment output, process layout, and adjustments. The main data circulating within these hanging equipment is order production data. In existing technologies, IoT sewing machines can collect operational data, but they cannot integrate this data with upper-level production conditions. Sewing machine data access is limited to the equipment level and cannot be accessed from production perspectives such as process and employee data.

[0003] For example, a Chinese patent document, "A Sewing Machine Control Method and System Based on Industrial Ethernet," with publication number CN107948282A, discloses a method in which a controller transmits control information to a corresponding driver via the EtherCAT communication protocol. The control information includes sewing information. The driver generates corresponding motion control information based on the received control information and sends it to the connected mechanical equipment. The mechanical equipment executes the corresponding sewing task based on the received motion control information. This invention utilizes the EtherCAT bus to connect the controller to the driver of the mechanical equipment, enabling unified control of multiple mechanical devices and achieving collaborative control of different mechanical devices. However, this solution only discloses how to issue sewing tasks and does not optimize for process flow-based control. Summary of the Invention

[0004] To address the problem that data from sewing equipment cannot be shared with the process and the entire workflow in existing technologies, this invention provides a method and system for synchronizing sewing equipment, which incorporates the parameters of the sewing machine into the process optimization control to achieve synchronous optimization of the entire process.

[0005] To achieve the above objectives, the present invention provides the following technical solution: A method for synchronizing sewing equipment includes the following steps: acquiring the process parameters of the sewing equipment and the operator's habitual parameters; determining the process score based on the process parameters and habitual parameters; and sending a production scheduling signal to the hanging equipment based on the process score. Multiple identical or different sewing machines are connected to the same network. The process parameters of each sewing machine and the information of the corresponding operator are acquired. The operator's habitual parameters are determined based on the operator's information. The process score for each operator's work on the machine is determined based on the process parameters and habitual parameters. The process score represents the operator's work efficiency for the corresponding process on the sewing machine. A process score is determined for each sewing machine. The process scores are used to create a production line balance table based on the hanging efficiency. Production is scheduled based on the production line balance table. This achieves automatic production scheduling, provides a process adjustment method, enables automatic process arrangement, saves industrial engineering time, and achieves full-process automatic optimization.

[0006] Preferably, the acquisition of process parameters for the sewing equipment includes: acquiring the electrical information of the sewing equipment and determining the process parameters based on this information; the process parameters include the sewing equipment's working efficiency and work progress. The sewing equipment is trained using historical work data to obtain different working efficiency ranges for various processes, and its standard working information is determined using the electrical information. These different efficiency ranges and standard working information are then stored as process parameters in the controller. Simultaneously, the actual physical position data of the sewing equipment relative to the hanging equipment is acquired, and the process data of the sewing equipment is obtained through a communication connection. By acquiring the process parameters and position of each sewing machine, monitoring of each machine is achieved, facilitating unified production scheduling.

[0007] Preferably, while acquiring the electrical information of the sewing equipment, the location data and process data of the sewing equipment are also acquired, and the electrical information is marked according to the corresponding location data and process data. The location data and process data of the sewing equipment are not included in the process parameters, but they can be used for production scheduling. By marking the location data and process data in the corresponding process parameters, after the production schedule is determined according to the process parameters, the production scheduling of the hanging equipment can be controlled based on the location data and process data, without the need for multiple data acquisitions, thus making the electrical information traceable.

[0008] Preferably, obtaining the operator's habitual parameters includes logging operator information through a sewing terminal, obtaining the corresponding habitual parameters, including stitch length and working speed, which are determined based on historical task completion volume. A sewing terminal is installed on the sewing equipment; this portable terminal is attached to the equipment. The sewing terminal is used to obtain habitual and process parameters. It obtains the equipment's process parameters via an electrical connection and the operator's habitual parameters via a network connection to a controller. The sewing terminal is also connected to the controller of the hanging equipment, with the controller located between the sewing terminal and the controller. Obtaining the operator's habitual parameters and the sewing equipment's process parameters through the sewing terminal facilitates synchronous control of different types and ages of sewing equipment, and facilitates the acquisition of data from different types and ages of sewing equipment, as well as data from different operators and different processes.

[0009] Preferably, determining the process score involves establishing correction functions for process parameters and habitual parameters. These correction functions yield detailed process data for each product, which is then used to determine the processing time. The process score is then calculated based on this data. The correction functions take process parameters and habitual parameters as input. Stitch pitch and stitch count from the habitual parameters are used as the first efficiency value. The working efficiency in the process parameters is corrected based on this first efficiency value, resulting in the second efficiency value. The working speed in the habitual parameters is then corrected based on this second efficiency value, resulting in the third efficiency value. This third efficiency value is then divided into individual piece data. The individual piece data is combined with the process parameters to obtain the actual working time for each piece. The actual working time for each piece is then combined with the position data of the sewing equipment and stored in the controller. By combining process parameters and habitual parameters using the process score to obtain the actual working time, inaccurate production scheduling results caused by inherent equipment characteristics or different operator habits are avoided. Furthermore, the cross-correction of process parameters and habitual parameters reduces scheduling errors.

[0010] As a preferred approach, after determining the processing time, a production line balance sheet is generated based on the processing time, and the process score is obtained from the production line balance sheet. A data list for each sewing machine is established based on the actual working hours, serving as the production line balance sheet. The production line balance sheet records the time for each process of a single piece on each sewing machine. The time of the last process of a single piece is sorted, and the current process score for each workpiece is determined based on the production line balance sheet, thus enabling production scheduling. By iterating through the process times of single pieces on all sewing machines using the production line balance sheet, production scheduling can be achieved for the specific process time of each sewing machine for each operator. This improves scheduling efficiency and accuracy. It also enables the uploading of small data blocks and allows for overall, multi-dimensional monitoring of the production process.

[0011] A sewing equipment synchronization system includes sewing equipment connected to hanging devices. Both the sewing equipment and the hanging devices are connected to a controller. The controller receives information from the sewing equipment and the hanging devices and generates process scores. The hanging devices are connected to a production control system, which sends control information to the hanging devices based on the process scores. Multiple hanging devices are used to perform hanging actions at the positions of each sewing equipment. The controller acquires data generated by the hanging devices and the sewing equipment. The production control system schedules production for the hanging devices based on the production information from the sewing equipment. By unifying the control of the sewing equipment and the hanging devices through the production control system, efficient production scheduling is achieved.

[0012] Preferably, the sewing equipment is connected to a sewing terminal, which is connected to a position sensor. The sewing terminal is used to acquire data on the sewing equipment during operation and the operator's habitual parameters. The position sensor is used to detect the distance between the sewing equipment and the hoisting equipment. The sewing terminal communicates with the controller. The sewing terminal enables unified access to different sewing equipment, especially among different intelligent devices, facilitating production scheduling and monitoring.

[0013] The present invention has the following advantages: (1) It realizes automatic production scheduling, provides a process adjustment tool, enables automatic process arrangement, saves IE time, realizes full-process automatic optimization, and realizes unified production scheduling for multiple different sewing equipment by connecting multiple sewing equipment through communication, realizing the networking of each different sewing equipment; (2) It facilitates the monitoring of process data in various dimensions, facilitates the evaluation of employee skills, and makes targeted arrangements for sewing machine operators' work, thereby improving sewing machine operator productivity; (3) It reduces production scheduling errors by cross-correcting process parameters and habitual parameters, and realizes accurate production scheduling for each operator at each sewing machine's specific process time. It improves production scheduling efficiency and accuracy; production can be traced according to process details, which facilitates the analysis of the causes of quality problems, facilitates the prompting of abnormal processes in the quality inspection process, and improves sewing quality. Attached Figure Description

[0014] The accompanying drawings described below are merely exemplary. Those skilled in the art can derive other embodiments from the provided drawings without any creative effort.

[0015] Figure 1 This is a schematic diagram of a sewing equipment synchronization system according to the present invention.

[0016] Figure 2 This is a block diagram of a synchronization system for a sewing equipment according to the present invention.

[0017] Figure 3 This is a schematic diagram of the working logic of the hanging equipment in Embodiment 3.

[0018] Figure 4 This is a schematic diagram of the division of single-item data in this invention.

[0019] Figure 5 This is a schematic representation of production line balance in this invention.

[0020] In the picture: 1-Sewing equipment; 2-Hanging equipment; 3-Controller; 4-Production control system; 5-Controller. Detailed Implementation

[0021] The following specific embodiments illustrate the implementation of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0022] As shown in Figure 1, in a preferred embodiment, this invention discloses a method for synchronizing sewing equipment, comprising: before acquiring the process parameters of the sewing equipment and the operator's habitual parameters, establishing a sewing equipment network, and connecting the sewing equipment and hanging equipment to the same controller 5. Specifically, multiple sewing equipment and hanging equipment are connected for communication, and the controller is used to control the hanging equipment according to the information of the sewing equipment. By connecting multiple sewing equipment for communication, each different sewing equipment is networked, achieving unified production scheduling for multiple different sewing equipment.

[0023] In use, devices with built-in communication capabilities are assigned a network address to connect them to the same system as the hanging equipment. Older equipment still in use is fitted with a sewing terminal, which includes a microprocessor connected to a communication circuit. This communication circuit connects the sewing terminal to the hanging equipment within the same system. The controller is located within this system.

[0024] The process parameters of the sewing equipment and the operator's habitual parameters are acquired. This acquisition includes obtaining the electrical information of the sewing equipment and determining the process parameters based on that information. The process parameters include the sewing equipment's working efficiency and progress. Simultaneously, the location and process data of the sewing equipment are acquired, and the electrical information is marked based on these data. While the location and process data are not included in the process parameters, they can be used for production scheduling. Marking these data in the corresponding process parameters allows for control of the hanging equipment's scheduling based on the combined location and process data after determining the scheduling, eliminating the need for multiple data acquisitions and ensuring the traceability of the electrical information. The sewing equipment is trained using historical working data to obtain different working efficiency ranges for various processes. Standard working information is acquired through an electrical connection with the sewing equipment's processor, and these different efficiency ranges and standard working information are stored as process parameters in the controller. Simultaneously, the actual physical position data of the sewing equipment relative to the hanging equipment is acquired, and the sewing equipment's process data is obtained through a communication connection. The implementation of obtaining operator habit parameters includes logging operator information through a sewing terminal, obtaining corresponding habit parameters, such as stitch length and work rate, which are influenced by personal habits and are determined based on historical task completion volume. A sewing terminal is installed on the sewing equipment; this portable terminal is used to obtain habit parameters and process parameters. The sewing terminal obtains the sewing equipment's process parameters via an electrical connection, and obtains the operator's habit parameters via a network connection to the controller. The sewing terminal is also connected to the controller of the hanging equipment, with the controller located between the sewing terminal and the controller.

[0025] The process score is determined based on process parameters and custom parameters, and a production scheduling signal is sent to the hanging equipment based on the process score. Determining the process score involves establishing correction functions for the process parameters and custom parameters, obtaining detailed process data for each product's current process using these functions, determining the processing time based on this detailed data, and then determining the process score based on the processing time. The inputs to the correction function include process parameters and custom parameters. The stitch pitch and stitch count from the custom parameters are used as the first efficiency value. The working efficiency in the process parameters is corrected based on this first efficiency value and used as the second efficiency value. The working speed in the custom parameters is corrected based on this second efficiency value and used as the third efficiency value. This third efficiency value is then divided into individual piece data, such as... Figure 4 As shown, the actual working time for a single piece is obtained by combining the data of a single piece with the process parameters. This actual working time is then combined with the position data of the sewing equipment and stored in the controller. For example... Figure 5As shown, after determining the processing time, a production line balance sheet is obtained based on the processing time. A process score is then obtained from the production line balance sheet, and the hanging equipment is controlled for production scheduling based on the process score. A data list for each sewing machine is established based on the actual working hours and serves as the production line balance sheet. The production line balance sheet records the time for each process of a single piece on each sewing machine. The time of the last process of a single piece is sorted to determine the production schedule.

[0026] The correction function includes a dynamic correction coefficient, which converts each efficiency value into a percentage and uses it as the dynamic correction coefficient for multiplication.

[0027] In use, multiple identical or different sewing machines are connected to the same network. The process parameters of the sewing machine and the information of the corresponding operator are obtained through the electrical information of the sewing machine. The operator's habitual parameters are determined based on the information of the operator. The process score of the operator's work on the machine is determined based on the process parameters and habitual parameters. The process score is used to represent the operator's work efficiency for the corresponding process on the sewing machine. The process score is determined for each sewing machine. The process score is used to make a production line balance table based on the hanging efficiency. Production is scheduled according to the production line balance table.

[0028] like Figure 2 As shown, in the second embodiment, the present invention discloses a sewing equipment synchronization system, including a sewing equipment 1, a hanging device 2 connected to the sewing equipment 1, and a controller 3 connected to both the hanging device 2 and the sewing equipment 1. The controller receives information from the sewing equipment and the hanging device and generates a process score. The hanging device is connected to a production control system 4, which sends control information to the hanging device according to the process score. The hanging device includes multiple hanging devices used to perform hanging actions at the position of each sewing equipment. The controller stores data generated by the hanging device and the sewing equipment. The production control system is used for production scheduling. The sewing equipment is connected to a sewing terminal, which is connected to a position sensor. The sewing terminal is used to acquire data from the sewing equipment during operation and the operator's habitual parameters. The position sensor detects the distance between the sewing equipment and the hanging device, and the sewing terminal is communicatively connected to the controller.

[0029] In use, the controller is located within the production control system and is used for production scheduling control. A sewing terminal is added to the existing sewing equipment. The sewing terminal receives tasks from the production control system, and the operator obtains custom parameters and other data from the controller through the sewing terminal. The production control system obtains operator information from the sewing terminal and corresponding custom parameters from the controller. After implementing the above method, the production control system schedules production through the controller.

[0030] In the third embodiment, the sewing device connects to the controller via a RS-232 data cable and binds its physical location to determine its current station position. After binding the station, the sewing device can access the controller via Wi-Fi to obtain the current station data. Furthermore, the device can interface with third-party MES and IoT systems, and the controller's IoT server retains third-party interfaces.

[0031] In fact, the physical location of the sewing equipment is pre-set in the controller via the 232 data cable. When the controller obtains electrical information from the sewing equipment, it no longer obtains data such as the location information of the sewing equipment at the same time. After obtaining the electrical information, it binds it to the physical location of the sewing equipment based on the address of the electrical information.

[0032] like Figure 3 As shown, when the hanging equipment is working, the sewing machine starts up and obtains the operating status of the hanging equipment. Upon successful acquisition, the station number is used as the address to retrieve the hanging data. Sewing machine data is acquired periodically, and hanging data is updated periodically. A controller message is sent after a change in the output of the hanging station. In other words, in this solution, the controller controls the hanging equipment based on the information from the sewing machine and periodically adjusts the operation of the hanging equipment according to the information from the sewing machine.

[0033] After the data is aggregated on the controller, the sewing machine data is divided according to the changes in hanging output. Detailed data for each process is reported to the controller database. Based on the processing time of different stations, a production line balance table is generated for each group. Based on the database, a multi-dimensional process library is established, which can search data from multiple dimensions such as employee, process, group, order, and sewing equipment model. Based on the above process library, after the hanging process is imported, automatic production scheduling is performed according to the employee's process score. Stitch distance is monitored by group and process, and displayed on the server. Sewing equipment parameter import: When the operator changes the workstation and process, the sewing machine obtains the process suggestion configuration from the server and the employee's habitual configuration. The configuration can be disabled by the operator or issued by the manager on the server and the parameters are locked. Quality inspection focus reminder: When the processing data of a certain process is relatively abnormal, a reminder will be given at the quality inspection station for focused inspection. The process suggestion configuration is the fastest configuration among the process scores of the current process, and the server is a monitoring terminal connected to the controller.

[0034] Although the present invention has been described in detail above with general descriptions and specific embodiments, modifications or improvements can be made to it, which will be obvious to those skilled in the art. Therefore, all such modifications or improvements made without departing from the spirit of the present invention fall within the scope of protection claimed by the present invention.

Claims

1. A method for synchronizing sewing equipment, characterized in that, Includes the following steps: Obtain the process parameters of the sewing equipment and the habitual parameters of the operators; Establish correction functions for process parameters and custom parameters. Use the pin pitch and pin count in the custom parameters as the first efficiency value. Correct the working efficiency in the process parameters based on the first efficiency value to obtain the second efficiency value. Correct the working speed in the custom parameters based on the second efficiency value to obtain the third efficiency value. Divide the third efficiency value into individual piece data. Combine the individual piece data with the process parameters to obtain the actual working time of the individual piece. Determine the process score based on the actual working time. Send the production scheduling signal to the hanging equipment based on the process score.

2. The method for synchronizing sewing equipment according to claim 1, characterized in that, The process of obtaining the sewing equipment's process parameters includes obtaining the electrical information of the sewing equipment and determining the process parameters based on the electrical information; the process parameters include the sewing equipment's working efficiency and working progress.

3. The method for synchronizing sewing equipment according to claim 2, characterized in that, While acquiring the electrical information of the sewing equipment, the system also acquires the position data and process data of the sewing equipment, and marks the electrical information based on the position data and process data of the corresponding sewing equipment.

4. A method for synchronizing sewing equipment according to claim 1, 2, or 3, characterized in that, The implementation of obtaining the operator's habit parameters includes logging in the operator's information through the sewing terminal, obtaining the habit parameters corresponding to the operator's information, including stitch length and working speed, and the habit parameters are determined based on the historical task completion volume.

5. The method for synchronizing sewing equipment according to claim 1, characterized in that, After determining the processing time, a production line balance sheet is obtained based on the processing time, and the process score is obtained based on the production line balance sheet.

6. A sewing equipment synchronization system, applicable to the sewing equipment synchronization method as described in any one of claims 1 to 5, characterized in that, It includes sewing equipment, which is connected to a hanging device. The hanging device and the sewing equipment are both connected to a controller. The controller receives information from the sewing equipment and the hanging device and generates a process score. The hanging device is connected to a production control system, which sends control information to the hanging device based on the process score.

7. A sewing equipment synchronization system according to claim 6, characterized in that, The sewing equipment is connected to a sewing terminal, which is connected to a position sensor. The sewing terminal is used to acquire data on the operation of the sewing equipment and the operator's habitual parameters.

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