An intelligent supervision system and method for a digital-based clothing production line

Abstract

The present invention relates to the field of clothing production, and specifically to an intelligent supervision system and method for a clothing production line based on digitization, including: a sewing digitization module, a fabric stitching module, a light-sensing backstitching module, an intelligent thread feeding module, and a production line management module. The sewing digitization module is used to establish a digital model of clothing; the fabric stitching module is used to control the position, penetration depth, and penetration force of the stitches of the flat sewing machine and stitch the fabric. The light-sensing backstitching module is used to judge the actual penetration position and backstitch the misaligned stitches. The intelligent thread feeding module is used to adjust the penetration and thread feeding parameters. The production line management module is used to detect the faults of the flat sewing machines and exchange tasks with other flat sewing machines. The present invention realizes the cooperation of the control device with the sewing device, the feeding device, and the positioning device, uniformly manages all flat sewing machines and avoids faults, making the sewing process more time-saving and labor-saving.

Description

Technical Field

[0001] The present invention relates to the technical field of clothing production, and particularly to an intelligent supervision system and method for a clothing production line based on digitization. Background Art

[0002] In modern clothing production, there are clothing production equipment such as high-speed lockstitch sewing machines, overlock sewing machines, cutting beds, buttonholing machines, etc. Among them, the industrial lockstitch sewing machine consists of a workbench, a feeding device, a clamping device, a positioning device, and a sewing device. Its sewing speed can reach 4000 - 5000 rpm, and the stitch formed is neat, uniform, flat, and firm, becoming the basic equipment in clothing production.

[0003] However, the speed and depth of each needle insertion of the traditional lockstitch sewing machine are the same. When dealing with relatively thin and light fabrics, the needle of the lockstitch sewing machine can easily penetrate the fabric and cause it to deform or be damaged. When penetrating and sewing thick fabrics, the depth and strength of the stitches are limited, and the lockstitch sewing machine may not be able to effectively penetrate and sew. At the same time, although the sewing speed of the lockstitch sewing machine is very fast, the accuracy is relatively low. Therefore, for projects that require high sewing accuracy, the traditional lockstitch sewing machine may have problems such as stitch misalignment and the opening of the lock when buttoning.

[0004] In addition, the sewing steel needle of the lockstitch sewing machine hits the workbench hundreds of times per minute, and the tip of the needle is very easy to wear. As the sewing process progresses, with the same needle insertion force, the needle insertion depth of the lockstitch sewing machine will decrease, and it may not be able to complete the sewing of the current clothing. At this time, turning off the lockstitch sewing machine will not only cause loss of efficiency, but also disrupt the production rhythm of the upstream and downstream processes, and even cause chaos in the entire production line. Summary of the Invention

[0005] The purpose of the present invention is to provide an intelligent supervision system and method for a clothing production line based on digitization to solve the problems raised in the above background art.

[0006] To solve the above technical problems, the present invention provides the following technical solution: An intelligent supervision system for a clothing production line based on digitization, including: a sewing digitization module, a fabric sewing module, a light-sensing backstitch module, an intelligent thread feeding module, and a production line management module;

[0007] The sewing digitization module is used to establish a digital model for the clothing to be sewn;

[0008] The fabric sewing module is used to feed the fabric and sew the fabric according to the model by controlling the position, needle insertion depth, and needle insertion force of the stitches of the lockstitch sewing machine;

[0009] The light-sensing backstitch module is used to judge the actual needle insertion position after needle insertion, backstitch the misaligned stitches, and record the needle insertion data;

[0010] The intelligent thread feeding module is used to adjust the needle insertion and thread feeding parameters after multiple backstitching, and determine the thread feeding tension and stitch density of the lockstitch sewing machine when sewing buttonholes;

[0011] The production line management module is used to detect the steel needle faults of the lockstitch sewing machine, judge the maximum needle insertion depth of the faulty lockstitch sewing machine, read the clothing models of other lockstitch sewing machines, and exchange the sewing tasks of the faulty lockstitch sewing machine with the tasks of other lockstitch sewing machines.

[0012] Furthermore, the sewing digitization module includes: a physical modeling unit and a digital modeling unit;

[0013] The physical modeling unit is used to construct a three-dimensional model according to the finished clothing using Solid works and invento technical software;

[0014] The digital modeling unit is used to fit the model of the clothing according to the production parameters of the worker sewing the clothing to obtain a three-dimensional model of the clothing.

[0015] Furthermore, the fabric sewing module includes: a piece overlapping unit, a dynamic needle insertion unit and a fabric sewing unit;

[0016] The piece overlapping unit is used to control the feeding device to feed the appropriate clothing fabric according to the established clothing model, overlap the fabric through the feed roller in front of the lockstitch sewing machine box, and feed it into the sewing area;

[0017] The dynamic needle insertion unit is used to calculate the needle insertion depth and needle insertion force of the lockstitch sewing machine according to the type and thickness of the fabric, locate the needle insertion position according to the three-dimensional model, and recalculate the parameters each time the needle is inserted during the sewing process;

[0018] The fabric sewing unit is used to control the fabric to enter the sewing channel according to the sewing speed of the lockstitch sewing machine, and sew the fabric according to the calculated parameters;

[0019] This module avoids the problems of the lockstitch sewing machine damaging thin fabrics and being unable to penetrate thick fabrics, and eliminates the need for manual parameter adjustment, making the sewing process more time-saving and labor-saving.

[0020] Furthermore, the optical sensor backstitching module includes: a needle insertion recognition unit and a backstitching unit;

[0021] The needle insertion recognition unit consists of a laser emission device on one side of the sewing channel and a light-sensitive device on the other side of the sewing channel, and is used to confirm the actual needle insertion position and actual needle insertion depth of the sewing machine;

[0022] The backstitching unit is used to back the lockstitch sewing machine to the previous stitch and sew again when the needle insertion position is abnormal or the needle fails to penetrate the fabric.

[0023] Furthermore, the intelligent thread inlet module includes: a thread inlet adjustment unit and a keyhole fine sewing unit;

[0024] The thread inlet adjustment unit is used to adjust the system parameters according to the backstitch situation and the needle insertion situation when multiple backstitches are detected, so as to reduce the impact caused by the failure of the lockstitch sewing machine;

[0025] The keyhole fine sewing unit is used to detect the keyholes in the clothing model and control the thread inlet tension and stitch density when sewing the keyholes according to the buttoning specifications of the downstream buttoning machine;

[0026] This module avoids the phenomenon of thread breakage during buttoning of high-precision sewn clothing, ensures the effective sewing of the fabric, improves the service life of the easily worn areas of the clothing, and makes the sewn clothing more durable and beautiful.

[0027] Furthermore, the production line management module includes: a fault supervision unit, a thread withdrawal unit and a process exchange unit;

[0028] The fault supervision unit is used to detect the looseness of the body connection and the steel needle wear fault of the lockstitch sewing machine and mark the faulty lockstitch sewing machine;

[0029] The thread withdrawal unit is used to detect the actual needle insertion depth of the faulty lockstitch sewing machine through the backstitch operation;

[0030] The process exchange unit is used to read the clothing models of other lockstitch sewing machines for producing different clothes, select appropriate clothes for sewing according to the actual needle insertion depth of the faulty lockstitch sewing machine, and complete the production exchange through the material clamping device and the feeding device;

[0031] The present invention can realize the unified management of all lockstitch sewing machines, reduce the production cost, improve the production efficiency, and ensure that the downstream processes are not interfered by the faults of some lockstitch sewing machines.

[0032] A digital-based intelligent supervision method for a clothing production line includes the following steps:

[0033] S100. According to the physical object of the clothing to be sewn or its production parameters, establish a three-dimensional model of the clothing to be sewn, and obtain the fabric information and keyhole information on each sewing line in the clothing;

[0034] S200. According to the clothing model established in step S100, control the material clamping device to feed the corresponding clothing fabric, overlap the fabrics and feed them into the sewing area; according to the fabric information obtained in step S100, further control the position, needle insertion depth and needle insertion force of the lockstitch sewing machine needle to sew the fabric; according to the keyhole information of the clothing, adjust the thread inlet length and stitch density when sewing the keyholes;

[0035] After the needle enters the sewing machine in S300, the actual needle insertion depth is judged by the photosensitive channel, the stitches that are not fully inserted are backstitched, and the needle insertion data is recorded; after continuous backstitching, it is determined that the tip of the sewing machine needle is worn, and the wear degree of the tip of the sewing machine needle is judged according to the actual needle insertion data, and a command for parameter adjustment is sent to the sewing machine;

[0036] S400. According to the wear degree of the tip of the sewing machine needle obtained in step S300, the needle insertion force of the sewing machine during the sewing process is further adjusted. When the adjustment upper limit is reached, enter the task switching process and go to step S500;

[0037] S500. Obtain the clothing model and production progress established by other sewing machines in the workshop, select a suitable clothing model according to the actual needle insertion depth of the faulty sewing machine, and continue sewing. The tasks of the two sewing machines are exchanged through the material clamping device and the feeding device.

[0038] Further, step S100 includes:

[0039] Step S101. The user selects a modeling method. If the user can provide a physical object of the finished clothing, directly use Solid works and invento technical software to construct a three-dimensional model;

[0040] Step S102. If the user cannot provide a physical object, read the production parameters for sewing the clothing. The production parameters include: the size of the clothing, the position of the fabric connection, the number of fabric layers, and the type of fabric. Construct a three-dimensional model of the clothing according to the production parameters;

[0041] Step S103. In the three-dimensional model, set the fabric connection and the edge of the buttonhole as the sewing thread, measure the fabric information and buttonhole information on the sewing thread. The fabric information includes: the number of fabric layers, fabric type, and fabric thickness at both ends of the fabric connection. The buttonhole information includes: the radius of the buttonhole and the specifications of the factory button machine.

[0042] Further, step S200 includes:

[0043] Step S201. According to the established clothing model, control the material clamping device to feed the appropriate clothing fabric, overlap the fabrics through the feed roller in front of the sewing machine box, and feed them into the sewing area;

[0044] Step S202. Calculate the needle insertion depth and needle insertion force of the sewing machine according to the number of fabric layers, type, and thickness, and calculate according to the following formula:

[0045]

[0046] Among them, S represents the needle insertion depth of the flat sewing machine, F represents the needle insertion force of the flat sewing machine, a represents the distance from the initial position of the steel needle to the workbench, i represents the layer number of the fabric, n represents the number of fabric layers, Pi represents the thickness of the i-th layer of fabric, Hi represents the force required for the unworn steel needle to penetrate one millimeter thickness of the i-th layer of fabric. All the above parameters are greater than 0, and n and i are positive integers;

[0047] Step S203. Locate the needle insertion position according to the sewing thread measured in step S103, and start the sewing process; during the sewing process, recalculate the parameters according to the steps of S202 every time the needle is inserted once;

[0048] Step S204. Detect the buttonhole in the clothing model. When sewing the buttonhole, calculate the length of the thread inserted and the stitch density during sewing according to the radius of the buttonhole and the buttoning specification of the factory buttoning machine using the following formula:

[0049]

[0050] Among them, L represents the length of the thread inserted, R represents the radius of the button when buttoning by the buttoning machine, r represents the radius of the buttonhole on the clothing, F0 represents the force required for the sewing thread to be stretched by one unit, F1 represents the maximum tension that a sewing thread of one unit of original length can withstand within the safe range, e represents the distance from the sewing thread to the edge of the buttonhole on the clothing, and Q represents the total number of stitches on the sewing thread.

[0051] Further, step S300 includes:

[0052] Step S301. After the flat sewing machine inserts the needle, the laser emission device on one side of the sewing channel emits laser to the other side, and the photosensitive device on the other side of the sewing channel receives the laser. The laser emission device and the photosensitive device are located in the groove under the workbench, and the actual needle insertion position and needle insertion depth are obtained from the reading of the photosensitive device;

[0053] Step S302. When the actual needle insertion position is different from the predetermined needle insertion position, or no needle insertion is detected, the flat sewing machine is retracted to the previous stitch, and sewing is carried out again. At the same time, the needle insertion data is recorded. The needle insertion data includes: the predetermined needle insertion depth, the actual needle insertion depth, and the fabric thickness at the backstitch position;

[0054] Step S303. After the number of consecutive backstitches exceeds the threshold R, it is determined that the tip of the flat sewing machine needle is worn, and the wear degree T of the needle tip is calculated according to the following formula:

[0055]

[0056] Among them, j represents the number of backstitch times, Sj represents the predetermined needle insertion depth at the j-th backstitch, Sj′ represents the actual needle insertion depth at the j-th backstitch, and Wj represents the total thickness of the clothing fabric at the j-th backstitch.

[0057] Further, step S400 includes:

[0058] Step S401. Calculate the needle insertion force F of the adjusted lockstitch sewing machine based on the needle tip wear degree obtained in step S300 ’ :

[0059]

[0060] where F represents the initial needle insertion force calculated in step S200, T is the wear degree of the needle tip, n represents the number of fabric layers, and Pi represents the thickness of the i-th layer of fabric;

[0061] Step S402. When the adjusted needle insertion force F ’ is greater than the force adjustment upper limit of the lockstitch sewing machine, enter the task exchange process, exchange the production content with other lockstitch sewing machines, and go to step S500;

[0062] The needle insertion force F calculated in step S200 is a predicted value calculated based on an unworn steel needle. However, during actual operation, the needle tip of the steel needle wears, which will cause a decrease in the needle insertion depth at the same force. This step can calibrate the needle insertion force of the lockstitch sewing machine according to the actual wear situation.

[0063] Further, step S500 includes:

[0064] Step S501. Read the clothing models and work progress of other lockstitch sewing machines for producing different clothes. When the fabric thickness of the unfinished part of the clothes is less than the actual needle insertion depth of the faulty lockstitch sewing machine, mark the lockstitch sewing machine producing this clothing as the to-be-exchanged state. When there is no to-be-exchanged lockstitch sewing machine, send an alarm to the user to notify the user to replace the steel needle of the faulty lockstitch sewing machine;

[0065] Step S502. Exchange the fabric and semi-finished clothes of the faulty lockstitch sewing machine and the to-be-exchanged lockstitch sewing machine through the material clamping device, and the feeding device feeds the new fabric and semi-finished clothes into the sewing channels of the corresponding lockstitch sewing machines;

[0066] Step S503. Exchange the system data of the two lockstitch sewing machines. After restarting the two lockstitch sewing machines, continue the sewing of the clothes.

[0067] Compared with the prior art, the beneficial effects achieved by the present invention are:

[0068] 1. The present invention can model clothes according to physical objects or production parameters, automatically feed materials according to the established model, and adjust the stitch position and depth of the flat sewing machine according to the number of layers and thickness of the fabric, realizing the cooperation of the control device with the sewing device, the feeding device, and the positioning device, avoiding the problems of damage to thin fabrics by the flat sewing machine and inability to penetrate thick fabrics, and eliminating the need for manual parameter adjustment, making the sewing process more time-saving and labor-saving.

[0069] 2. The present invention can adjust the thread tension and stitch density according to the size of the buttonhole and the specification of the button, avoiding the phenomenon of thread breakage when buttoning clothes with high-precision sewing, ensuring the effective sewing of the fabric, improving the service life of the easily worn areas of the clothes, and making the sewn clothes more durable and beautiful.

[0070] 3. Through photosensitive design, the present invention can judge the needle insertion position after the needle enters the flat sewing machine, perform a backstitch operation on the needle insertion position. After multiple backstitches, it can judge the wear condition of the needle tip according to the needle insertion data and dynamically adjust the needle insertion force, ensuring that the flat sewing machine can still operate and improving the anti-fault ability of the flat sewing machine.

[0071] 4. When the flat sewing machine has a minor steel needle fault and cannot complete the sewing of the current clothes, the present invention can read the clothes models established by other flat sewing machines, select the clothes with thinner fabrics among them, and perform production exchange between different flat sewing machines through the clamping device and the feeding device, ensuring the stability of the sewing process. It realizes the unified management of all flat sewing machines, reduces the production cost, improves the production efficiency, and ensures that the downstream processes are not interfered by the faults of some flat sewing machines. BRIEF DESCRIPTION OF THE DRAWINGS

[0072] The drawings are used to provide a further understanding of the present invention, and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention, but do not constitute a limitation to the present invention. In the drawings:

[0073] Figure 1 is a schematic structural diagram of an intelligent supervision system for a digital-based clothing production line according to the present invention;

[0074] Figure 2 is a schematic step diagram of an intelligent supervision method for a digital-based clothing production line according to the present invention; DETAILED DESCRIPTION OF THE EMBODIMENTS

[0075] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0076] Please refer to Figure 1 , the present invention provides a technical solution: an intelligent supervision system for a clothing production line based on digitization, including: a sewing digitization module, a fabric stitching module, a light-sensing backstitching module, an intelligent thread feeding module, and a production line management module;

[0077] The sewing digitization module is used to establish a digital model for the clothing to be sewn;

[0078] The sewing digitization module includes: a physical modeling unit and a digital modeling unit;

[0079] The physical modeling unit is used to construct a three-dimensional model according to the finished clothing using Solid works and invento technical software;

[0080] The digital modeling unit is used to fit the model of the clothing according to the production parameters of the worker sewing the clothing to obtain a three-dimensional model of the clothing;

[0081] The fabric stitching module is used to feed the fabric and stitch the fabric according to the position, penetration depth and penetration force of the flat sewing machine needle controlled by the model;

[0082] The fabric stitching module includes: a piece overlapping unit, a dynamic needle penetration unit and a fabric stitching unit;

[0083] The piece overlapping unit is used to control the clamping device to feed the appropriate clothing fabric according to the established clothing model, overlap the fabric through the feed roller in front of the flat sewing machine box body, and feed it into the sewing area;

[0084] The dynamic needle penetration unit is used to calculate the penetration depth and penetration force of the flat sewing machine needle according to the type and thickness of the fabric, locate the needle penetration position according to the three-dimensional model, and recalculate the parameters every time the needle penetrates during the sewing process;

[0085] The fabric stitching unit is used to control the fabric to enter the sewing channel according to the sewing speed of the flat sewing machine and stitch the fabric according to the calculated parameters;

[0086] The light-sensing backstitching module is used to judge the actual needle penetration position after the needle penetrates, backstitch the misaligned stitches, and record the needle penetration data;

[0087] The light-sensing backstitching module includes: a needle penetration recognition unit and a backstitching unit;

[0088] The needle penetration recognition unit is composed of a laser emission device on one side of the sewing channel and a light-sensing device on the other side of the sewing channel, and is used to confirm the actual needle penetration position and actual penetration depth of the sewing machine;

[0089] The backstitching unit is used to detect that the needle penetration position is abnormal or the needle does not penetrate the fabric, and retract the flat sewing machine to the previous stitch and sew again;

[0090] The intelligent thread feeding module is used to adjust the needle insertion and thread feeding parameters after multiple backstitching, and determine the thread feeding tension and stitch density of the lockstitch sewing machine when sewing buttonholes;

[0091] The intelligent thread feeding module includes: a thread feeding adjustment unit and a precise buttonhole sewing unit;

[0092] The thread feeding adjustment unit is used to detect multiple backstitching, adjust system parameters according to the backstitching situation and needle insertion situation, and reduce the impact caused by the failure of the lockstitch sewing machine;

[0093] The precise buttonhole sewing unit is used to detect the buttonholes in the clothing model, and control the thread feeding tension and stitch density when sewing buttonholes according to the buttoning specifications of the downstream buttoning machine;

[0094] The production line management module is used to detect the steel needle failure of the lockstitch sewing machine, judge the maximum needle insertion depth of the faulty lockstitch sewing machine, read the clothing models of other lockstitch sewing machines, and exchange the sewing tasks of the faulty lockstitch sewing machine with the tasks of other lockstitch sewing machines;

[0095] The production line management module includes: a fault supervision unit, a thread retraction unit, and a process exchange unit;

[0096] The fault supervision unit is used to detect the loosening of the body connection and the steel needle wear fault of the lockstitch sewing machine, and mark the faulty lockstitch sewing machine;

[0097] The thread retraction unit is used to detect the actual needle insertion depth of the faulty lockstitch sewing machine through backstitching operations;

[0098] The process exchange unit is used to read the clothing models of other lockstitch sewing machines producing different clothes, select suitable clothes for sewing according to the actual needle insertion depth of the faulty lockstitch sewing machine, and complete the production exchange through the material clamping device and the feeding device;

[0099] As Figure 2 shown, a digital-based intelligent supervision method for a clothing production line includes the following steps:

[0100] S100. According to the physical object of the clothing to be sewn or its production parameters, establish a three-dimensional model of the clothing to be sewn, and obtain the fabric information and buttonhole information on each sewing line in the clothing;

[0101] Step S100 includes:

[0102] Step S101. The user selects a modeling method. If the user can provide the physical object of the finished clothing, directly use Solid works and invento technical software to construct a three-dimensional model;

[0103] Step S102. If the user cannot provide the physical object, read the production parameters for sewing the clothing, where the production parameters include: the size of the clothing, the positions of fabric connection, the number of fabric layers, and the type of fabric, and construct a three-dimensional model of the clothing according to the production parameters;

[0104] Step S103. In the three-dimensional model, set the fabric connection points and the edges of the buttonholes as sewing lines, and measure the fabric information and buttonhole information on the sewing lines. The fabric information includes: the number of fabric layers, the type of fabric, and the fabric thickness at both ends of the fabric connection point. The buttonhole information includes: the radius of the buttonhole and the specifications of the factory button sewing machine;

[0105] S200. According to the clothing model established in step S100, control the clamping device to feed the appropriate clothing fabric, overlap the fabrics and feed them into the sewing area; according to the fabric information obtained in step S100, further control the position, penetration depth, and penetration force of the flat sewing machine needle to sew the fabrics; according to the buttonhole information of the clothing, adjust the length of the thread entering the needle and the stitch density when sewing the buttonhole;

[0106] Step S200 includes:

[0107] Step S201. According to the established clothing model, control the clamping device to feed the appropriate clothing fabric, overlap the fabrics through the feed rollers in front of the flat sewing machine box body, and feed them into the sewing area;

[0108] Step S202. Calculate the penetration depth and penetration force of the flat sewing machine needle according to the number of fabric layers, type, and thickness, and calculate according to the following formula:

[0109]

[0110] where S represents the penetration depth of the flat sewing machine needle, F represents the penetration force of the flat sewing machine needle, a represents the distance from the initial position of the steel needle to the workbench, i represents the number of the fabric layer, n represents the number of fabric layers, Pi represents the thickness of the i-th fabric layer, Hi represents the force required for the steel needle to penetrate one millimeter of the i-th fabric layer, and the above parameters are all greater than 0, and n and i are positive integers;

[0111] Step S203. Locate the needle entry position according to the sewing line measured in step S103 and start the sewing process; during the sewing process, recalculate the parameters according to the steps of S202 every time the needle enters;

[0112] Step S204. Detect the buttonholes in the clothing model, set the holes in the middle of the whole fabric as buttonholes, and when sewing the buttonholes, calculate and control the length of the thread entering the needle and the stitch density according to the radius of the buttonhole and the button sewing specifications of the factory button sewing machine according to the following formula:

[0113]

[0114] Wherein, L represents the length of the incoming thread, R represents the radius of the buckle when the buckle machine is buckling, r represents the radius of the buttonhole on the clothing, F0 represents the force required for the sewing thread to be stretched by one unit, F1 represents the maximum tension that a sewing thread of one unit of original length can withstand within the safe range, e represents the distance from the sewing thread to the edge of the buttonhole on the clothing, Q represents the total number of stitches on the sewing thread, and when Q is not an integer, it is rounded up. All the above parameters are greater than 0;

[0115] S300. After the flat sewing machine inserts the needle, the actual needle insertion depth is judged by the photosensitive channel, the stitches that are not fully inserted are backstitched, and the needle insertion data is recorded; after continuous backstitching, it is determined that the tip of the flat sewing machine needle is worn, and the wear degree of the tip of the flat sewing machine needle is judged according to the actual needle insertion data, and a command for parameter adjustment is sent to the flat sewing machine;

[0116] Step S300 includes:

[0117] Step S301. After the flat sewing machine inserts the needle, a laser emitting device on one side of the sewing channel emits laser light to the other side, and a photosensitive device on the other side of the sewing channel receives the laser light. The laser emitting device and the photosensitive device are located in a groove under the workbench, and the actual needle insertion position and needle insertion depth are obtained from the reading of the photosensitive device;

[0118] Step S302. When the actual needle insertion position is different from the predetermined needle insertion position, or no needle insertion is detected, the flat sewing machine is retracted to the previous stitch and sewn again, and the needle insertion data is recorded at the same time. The needle insertion data includes: the predetermined needle insertion depth, the actual needle insertion depth, and the fabric thickness at the backstitch position;

[0119] Step S303. After the number of consecutive backstitches exceeds the threshold R, it is determined that the tip of the flat sewing machine needle is worn, and the wear degree T of the needle tip is calculated according to the following formula:

[0120]

[0121] Wherein, j represents the number of the backstitch times, Sj represents the predetermined needle insertion depth at the jth backstitch, Sj′ represents the actual needle insertion depth at the jth backstitch, and Wj represents the total thickness of the clothing fabric at the jth backstitch;

[0122] S400. According to the wear degree of the tip of the flat sewing machine needle obtained in step S300, the needle insertion force of the flat sewing machine during the sewing process is further adjusted. When the adjustment upper limit is reached, the task switching process is entered, and it turns to step S500;

[0123] Step S400 includes:

[0124] Step S401. Calculate the adjusted needle insertion force F of the flat sewing machine from the wear degree of the needle tip obtained in step S300 ’ :

[0125]

[0126] Among them, F represents the initial needle-insertion force, T represents the wear degree of the needle tip, n represents the number of fabric layers, and Pi represents the thickness of the i-th layer of fabric;

[0127] Step S402. When the adjusted needle-insertion force F ’ is greater than the upper limit of the force adjustment of the flat sewing machine, enter the task exchange process, exchange the production content with other flat sewing machines, and go to step S500;

[0128] S500. Obtain the clothing models and production progress established by other flat sewing machines in the workshop. According to the actual needle-insertion depth of the faulty flat sewing machine, select a suitable clothing model to continue sewing, and exchange the tasks of the two flat sewing machines through the material clamping device and the feeding device;

[0129] Step S500 includes:

[0130] Step S501. Read the clothing models and work progress of other flat sewing machines for producing different clothes. When the fabric thickness of the unfinished parts of the clothes is less than the actual needle-insertion depth of the faulty flat sewing machine, mark the flat sewing machine producing this clothing as the state to be exchanged. When there is no flat sewing machine to be exchanged, send an alarm to the user to notify the user to replace the steel needle of the faulty flat sewing machine;

[0131] Step S502. Exchange the fabrics and semi-finished clothes of the faulty flat sewing machine and the flat sewing machine to be exchanged through the material clamping device, and the feeding device feeds the new fabrics and semi-finished clothes into the sewing channels of the corresponding flat sewing machines;

[0132] Step S503. Exchange the system data of the two flat sewing machines. After restarting the two flat sewing machines, continue sewing the clothes.

[0133] Embodiment:

[0134] The user needs to sew a shirt and provides the production parameters of the shirt. A three-dimensional model of the clothing is constructed according to the production parameters; according to the established clothing model, the material clamping device is controlled to feed the appropriate clothing fabric, and the fabrics are overlapped by the feed rollers in front of the flat sewing machine box and fed into the sewing area;

[0135] Obtain the fabric information of the shirt, and obtain that the number of fabric layers at both ends of the fabric connection is 2, the type of the first layer of fabric is cotton, the fabric thickness is 8mm, the type of the second layer of fabric is chemical fiber, the fabric thickness is 2mm, the force required to penetrate 1mm of fabric is 1N, and the distance a from the initial position of the steel needle to the workbench is 50mm. Then calculate the needle-insertion depth S = 60mm and the needle-insertion force F = 10N on this sewing line, and sew according to the calculated parameters;

[0136] During the sewing process, a buttonhole with a radius of 10 mm is detected in the shirt model. The button-locking specification radius of the factory buttoning machine is 15 mm, F0 = 10 N, F1 = 5 N, e = 5 mm. Then, the thread inlet length L for sewing the buttonhole is calculated as L = 250π mm, and the number of stitches Q = 9. The buttonhole is sewn according to these parameters.

[0137] During the sewing process, the photosensitive device detects that the backstitch situation of the flat sewing machine is greater than the threshold R = 10, and it is determined that the needle tip is worn. After calculation, the wear degree T = 0.12. Then, the adjusted force F ’ = 12 N. However, the upper limit of the force of this flat sewing machine is 11 N, and the adjustment cannot be completed.

[0138] A command to replace the task is sent to the system, and the clothing models and work progress of other flat sewing machines for producing different clothes are read. It is detected that another flat sewing machine in the factory is sewing a single-piece clothing with a total fabric thickness of 2 mm. Then, the production contents of the two flat sewing machines are exchanged through the material clamping device and the feeding device, and the system data of the two flat sewing machines is exchanged. After restarting the two flat sewing machines, the sewing of the clothes continues.

[0139] It should be noted that in this article, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the term "including", "comprising" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements not only includes those elements, but also includes other elements not expressly listed, or also includes elements inherent to such process, method, article or device.

[0140] Finally, it should be noted that the above are only the preferred embodiments of the present invention and are not used to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements for some of the technical features. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. An intelligent supervision method for a digital-based clothing production line, characterized in that, The method includes the following steps: S100. Based on the physical object of the garment to be sewn or its production parameters, establish a three-dimensional model of the garment to be sewn, and obtain the fabric information and buttonhole information on each sewing line in the garment. S200. According to the garment model established in step S100, control the material clamping device to feed the corresponding garment fabric, overlap the fabrics and then feed them into the sewing area; according to the fabric information obtained in step S100, further control the position, penetration depth and penetration force of the flat sewing machine stitches to sew the fabric; according to the buttonhole information of the garment, adjust the thread feeding length and stitch density when sewing the buttonhole. S300. After the flat sewing machine penetrates the needle, the photosensitive channel judges the actual penetration depth, performs backstitching on the stitches that have not fully penetrated the needle, and records the needle penetration data; after continuous backstitching, it is determined that the tip of the flat sewing machine needle is worn. According to the actual needle penetration data, judge the wear degree of the tip of the flat sewing machine needle, and send a command for parameter adjustment to the flat sewing machine. S400. According to the wear degree of the tip of the flat sewing machine needle obtained in step S300, further adjust the penetration force of the flat sewing machine during the sewing process. When the adjustment upper limit is reached, enter the task switching process and go to step S500. S500. Obtain the garment models and production progress established by other flat sewing machines in the factory building. According to the actual penetration depth of the faulty flat sewing machine, select a suitable garment model to continue sewing, and exchange the tasks of the two flat sewing machines through the material clamping device and the feeding device.

2. The intelligent supervision method for a digital-based clothing production line according to claim 1, characterized in that: Step S100 includes: Step S101. The user selects a modeling method. If the user can provide the physical object of the finished garment, directly use Solidworks and inventor technical software to construct a three-dimensional model. Step S102. If the user cannot provide the physical object, read the production parameters for sewing the garment. The production parameters include: the size of the garment, the position of fabric connection, the number of fabric layers and the type of fabric, and construct a three-dimensional model of the garment according to the production parameters. Step S103. In the three-dimensional model, set the fabric connection points and the edges of the buttonholes as sewing lines, and measure the fabric information and buttonhole information on the sewing lines. The fabric information includes: the number of fabric layers, the type of fabric and the fabric thickness at both ends of the fabric connection point. The buttonhole information includes: the radius of the buttonhole and the specifications of the factory button sewing machine.

3. The intelligent supervision method for a digital-based clothing production line according to claim 2, wherein: Step S200 includes: Step S201. According to the established garment model, control the material clamping device to feed the appropriate garment fabric, overlap the fabrics through the feed rollers in front of the flat sewing machine box, and feed them into the sewing area. Step S202. Calculate the penetration depth and penetration force of the flat sewing machine needle according to the number of fabric layers, type and thickness of the fabric, and calculate according to the following formula: ； Where, S represents the penetration depth of the flat sewing machine needle, F represents the penetration force of the flat sewing machine needle, a represents the distance from the initial position of the steel needle to the workbench, i represents the number of fabric layer numbers, n represents the number of fabric layers, Pi represents the thickness of the i-th layer of fabric, Hi represents the force required for the unworn steel needle to penetrate one millimeter thickness of the i-th layer of fabric. The above parameters are all greater than 0, and n and i are positive integers. Step S203. Locate the needle - entry position according to the sewing thread measured in step S103, and start the sewing process; during the sewing process, recalculate the parameters according to the steps of S202 every time a needle enters. Step S204. Detect the buttonholes in the clothing model. When sewing buttonholes, calculate the control stitch density during buttonhole sewing according to the following formula: ； Where, L represents the length of the thread entry, r represents the radius of the buttonhole on the clothing, e represents the distance from the sewing thread to the edge of the clothing buttonhole, Q represents the stitch density, and Pi represents the thickness of the i - th layer of fabric.

4. A digital - based intelligent supervision method for a clothing production line according to claim 3, characterized in that: Step S300 includes: Step S301. After the needle enters the flat - bed sewing machine, a laser - emitting device on one side of the sewing channel emits laser light to the other side, and a photosensitive device on the other side of the sewing channel receives the laser. The laser - emitting device and the photosensitive device are located in a groove under the workbench, and the actual needle - entry position and needle - entry depth are obtained from the reading of the photosensitive device. Step S302. When the actual needle - entry position is different from the predetermined needle - entry position or no needle - entry is detected, the flat - bed sewing machine is retracted to the previous stitch, and sewing is restarted. At the same time, record the needle - entry data, and the needle - entry data includes: the predetermined needle - entry depth, the actual needle - entry depth, and the fabric thickness at the back - stitch position. Step S303. After the number of consecutive back - stitches exceeds the threshold R, it is determined that the tip of the flat - bed sewing machine is worn. Calculate the wear degree T of the needle tip according to the following formula: ； Among them, j represents the serial number of the number of backstitching times, represents the predetermined needle insertion depth during the j-th backstitching, represents the actual needle insertion depth during the j-th backstitching, and Wj represents the total thickness of the garment fabric during the j-th backstitching.

5. A digital - based intelligent supervision method for a clothing production line according to claim 4, characterized in that: Step S400 includes; Step S401. Calculate the needle insertion force of the adjusted lockstitch sewing machine based on the needle tip wear degree obtained in Step S300 : ； Where, F represents the initial needle - entry force calculated in step S200, T is the wear degree of the needle tip, n represents the number of fabric layers, and Pi represents the thickness of the i - th layer of fabric; Step S402. When the adjusted needle insertion force is greater than the upper limit of the force adjustment of the lockstitch sewing machine, enter the task exchange process, exchange the production content with other lockstitch sewing machines, and go to step S500; Step S500 includes: Step S501. Read the clothing models and work progress of other flat - bed sewing machines for producing different clothes. When the fabric thickness of the unfinished part of the clothing is less than the actual needle - entry depth of the faulty flat - bed sewing machine, mark the flat - bed sewing machine for producing this clothing as in a state to be exchanged. When there is no flat - bed sewing machine to be exchanged, send an alarm to the user to notify the user to replace the needle of the faulty flat - bed sewing machine. Step S502. Exchange the fabrics and semi - finished clothes of the faulty flat - bed sewing machine and the flat - bed sewing machine to be exchanged through the material - clamping device, and the feeding device feeds the new fabrics and semi - finished clothes into the sewing channels of the corresponding flat - bed sewing machines. Step S503. Exchange the system data of the two flat - bed sewing machines, restart the two flat - bed sewing machines, and then continue the sewing of the clothes.

6. An intelligent supervision system for a digital-based clothing production line, characterized in that, The system includes the following modules: a sewing digitization module, a fabric stitching module, a light - sensing back - stitch module, an intelligent thread - entry module, and a production - line management module; The sewing digitization module is used to establish a digital model for the clothes to be sewn. The fabric stitching module is used to feed the fabric and stitch the fabric according to the model by controlling the position, needle - entry depth, and needle - entry force of the flat - bed sewing machine. The fabric stitching module includes: a dynamic needle - entry unit and a fabric stitching unit; The dynamic needle insertion unit is used to calculate the needle insertion depth and needle insertion force of the lockstitch sewing machine according to the type and thickness of the fabric, locate the needle insertion position based on the three-dimensional model, and recalculate the parameters each time a needle is inserted during the sewing process; The fabric stitching unit is used to control the fabric to enter the sewing channel according to the sewing speed of the lockstitch sewing machine and stitch the fabric according to the calculated parameters; The light-sensing backstitch module is used to judge the actual needle insertion position after needle insertion, perform backstitching on misaligned stitches, and record the needle insertion data; The intelligent thread insertion module is used to adjust the needle insertion and thread insertion parameters after multiple backstitches, and determine the thread insertion tension and stitch density of the lockstitch sewing machine when sewing buttonholes; The production line management module is used to detect the steel needle failure of the lockstitch sewing machine, judge the maximum needle insertion depth of the faulty lockstitch sewing machine, and read the clothing models of other lockstitch sewing machines. When the adjusted needle insertion force is greater than the upper limit of the force adjustment of the lockstitch sewing machine, exchange the sewing tasks of the faulty lockstitch sewing machine with the tasks of other lockstitch sewing machines.

7. The intelligent supervision system for a digital-based clothing production line according to claim 6, characterized in that: The sewing digitization module includes: a physical modeling unit and a digital modeling unit; The physical modeling unit is used to construct a three-dimensional model using Solid works and inventor technical software according to the finished clothing; The digital modeling unit is used to fit the model of the clothing according to the production parameters of the worker sewing the clothing to obtain the three-dimensional model of the clothing.

8. The intelligent supervision system for a digital-based clothing production line according to claim 7, wherein: The fabric stitching module further includes: a piece overlapping unit; The piece overlapping unit is used to control the feeding device to feed the appropriate clothing fabric according to the established clothing model, overlap the fabric through the feed roller in front of the lockstitch sewing machine box, and feed it into the sewing area.

9. An intelligent supervision system for a digital-based clothing production line according to claim 8, characterized in that: The light-sensing backstitch module includes: a needle insertion recognition unit and a backstitch unit; The needle insertion recognition unit is composed of a laser emission device on one side of the sewing channel and a light-sensing device on the other side of the sewing channel, and is used to confirm the actual needle insertion position and actual needle insertion depth of the sewing machine; The backstitch unit is used to retract the lockstitch sewing machine to the previous stitch and sew again when the needle insertion position is abnormal or the needle fails to penetrate the fabric; The intelligent thread insertion module includes: a thread insertion adjustment unit and a buttonhole fine sewing unit; The thread insertion adjustment unit is used to adjust the system parameters according to the backstitch situation and needle insertion situation when multiple backstitches are detected, and reduce the impact caused by the lockstitch sewing machine failure; The buttonhole fine sewing unit is used to detect the buttonholes in the clothing model and control the thread insertion tension and stitch density when sewing buttonholes according to the buttoning specifications of the downstream buttoning machine.

10. The intelligent supervision system for a digital-based clothing production line according to claim 9, wherein: The production line management module includes: a fault supervision unit, a thread retraction unit, and a process exchange unit; The fault supervision unit is used to detect the loosening of the body connection and the wear of the steel needle of the lockstitch sewing machine and mark the faulty lockstitch sewing machine; The thread retraction unit is used to detect the actual needle insertion depth of the faulty lockstitch sewing machine through backstitch operation; The process exchange unit is used to read the clothing models of other lockstitch sewing machines producing different clothing, select appropriate clothing for sewing according to the actual needle insertion depth of the faulty lockstitch sewing machine, and complete the production exchange through the clamping device and the feeding device.

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