A pneumatic tufting sewing robot and a sewing method thereof

Abstract

This invention relates to a pneumatic tufting and sewing robot, comprising a six-degree-of-freedom robot, a tufting and sewing end effector, and a rotary worktable. The end of the six-degree-of-freedom robot's robotic arm is connected to the tufting and sewing end effector, which controls the sewing of a prefabricated fabric placed on the rotary worktable. The tufting and sewing end effector includes a displacement mechanism, a needle-punching mechanism, a presser foot mechanism, a yarn feeding mechanism, and a pneumatic shearing mechanism. The yarn feeding mechanism includes a yarn tube, a thread clamp, and a yarn breakage detection sensor. The yarn tube is mounted on a yarn tube connecting plate. A thread clamp is installed near one end of the connecting bracket close to the yarn tube, a thread feed rod is inserted in the middle, and a yarn breakage detection sensor is installed near the end of the tufting cylinder. Ceramic eyelets are provided on the connecting bracket and the thread feed rod. The rotary worktable device includes a combined mandrel, a mandrel mounting base, a rotary table, and a worktable. The invention also includes a sewing method using the above-described robot. This invention provides convenient adjustment of the tufting and sewing depth, stable control of the needle orientation, and high sewing efficiency.

Description

Technical Field

[0001] This invention belongs to the field of composite material preform tufting and sewing technology, and specifically relates to a pneumatic tufting and sewing robot and its sewing method. Background Technology

[0002] Composite materials, due to their lightweight, high strength, and excellent structural durability, are widely used in various industries, from sporting goods to aerospace vehicles. Tufting stitching can connect multiple layers of fabric and plays a role in composite materials mainly by enhancing interlayer properties, improving mechanical properties, forming three-dimensional reinforced structures, optimizing material design, and improving material durability. These characteristics make tufting stitching an important technical means for manufacturing high-performance composite materials.

[0003] The paper "3D reinforcement of stiffener-to-skin T-joints by Z-pinning and tufting" discloses a tufting sewing robot that uses a KSL KL150 tufting sewing end effector. It can be used for single-sided sewing of curved prefabricated fabrics. The end effector is driven by a motor and has a relatively complex overall structure. In addition, the system is not equipped with a seventh-axis rotary table, which makes it difficult to meet the tufting sewing needs of complex quasi-rotational prefabricated fabrics. Furthermore, it does not integrate motion compensation function for the tufting process, resulting in low sewing efficiency.

[0004] Chinese Patent 94194721.1 discloses a mechanical tufting head, suitable for handheld tufting guns or automatic tufting heads used to produce individual carpets. However, the uniformity of the stitching is difficult to control, and it cannot meet the quality requirements of tufted preforms.

[0005] The paper "Development and optimization of the tufting process for textile composite reinforcement" discloses a cylinder-based flat preform tufting sewing device. However, it cannot meet the tufting sewing requirements of curved and irregularly shaped preforms. The cylinder stroke is fixed, the tufting sewing depth is difficult to adjust, there is no yarn breakage detection and yarn tension control function, and there is no motion compensation function, resulting in low sewing efficiency.

[0006] In summary, existing tufting robots are not suitable for tufting and sewing complex, irregularly shaped prefabricated fabrics, therefore improvements to existing tufting equipment are necessary. Summary of the Invention

[0007] This invention provides a pneumatic tufting and sewing robot and its sewing method to solve the technical problems existing in the prior art. The mechanical structure of this invention is simple and easy to operate, the tufting and sewing depth is easy to adjust, the orientation of the sewing needle is stably controlled, and it can realize continuous movement during the robot tufting and sewing process without frequent start and stop, which greatly improves the sewing efficiency. It is suitable for tufting and sewing of complex irregular prefabricated fabrics.

[0008] This invention includes the following technical solutions:

[0009] A pneumatic tufting and sewing robot includes a six-degree-of-freedom robot, a tufting and sewing end effector, and a rotary table. The end effector of the six-degree-of-freedom robot is connected to the tufting and sewing end effector and controls it to sew a prefabricated fabric set on the rotary table. The tufting and sewing end effector includes a displacement mechanism, a needle punching mechanism, a presser foot mechanism, a yarn feeding mechanism, and a pneumatic shearing mechanism. The displacement mechanism includes a robot connecting flange, a linear module, and a detection switch. The robot connecting flange is fixed to a flange connecting plate and mounted on the linear module. The robot connecting flange can slide relative to the lead screw axis of the linear module. Detection switches are located at both ends of the lead screw slide of the linear module. A connecting plate is installed in the middle of the linear module, and a needle-punching mechanism is located at the other end of the connecting plate. The needle-punching mechanism includes a tufting cylinder, a wire feeding rod, a needle plate, and a needle. The tufting cylinder is installed on one side of the connecting plate, with a needle plate at the bottom and a wire feeding rod on the side. The needle is installed at the bottom of the needle plate via a needle connector. The presser foot mechanism includes a presser foot cylinder and a presser foot. The presser foot cylinder is installed on the other side of the connecting plate. The cylinder has a pressure foot at the bottom, with its base plate located below the needle. The piston rod of the pressure foot cylinder pushes the pressure foot to reciprocate for fixation. The reciprocating motion of the piston rod of the tufting cylinder drives the yarn feeding rod to feed yarn, which in turn drives the needle plate to reciprocate for needle punching. A cylinder connecting plate is installed on one end face of the connecting plate, and a yarn tube connecting plate and a connecting bracket are installed on the other end face. These three components are located on both sides of the tufting cylinder and the pressure foot cylinder. The yarn feeding mechanism includes a yarn tube, a yarn clamp, and a yarn breakage detection sensor. The yarn tube is installed on the yarn tube connecting plate, and the connecting bracket is installed near the yarn tube. The device includes a yarn clamp, a yarn feeding top rod inserted in the middle, and a yarn breakage detection sensor installed near the end of the tufting cylinder. A connecting bracket, yarn feeding top rod, and needle plate are equipped with ceramic eyelets. The air shearing mechanism includes pneumatic shears and a direct-drive cylinder. The direct-drive cylinder is fixedly mounted on a cylinder connecting plate, and the pneumatic shears are installed at the working end of the direct-drive cylinder. The rotary worktable includes a combined core mold, a core mold mounting base, a rotary table, and a worktable. A rotary table is set on the worktable, and a core mold mounting base is fixedly mounted on the rotary table. The core mold mounting base is connected to the combined core mold, and the surface of the combined core mold is covered with a combined foam base felt.

[0010] Furthermore, the detection switches are respectively installed at the starting and ending points of the lead screw slide by screws; the connecting plate is L-shaped as a whole, and the middle of the inner side of the right angle of the L-shape is fixed with reinforcing ribs by screws to improve the overall strength and enhance the resistance to deformation.

[0011] Furthermore, the robot connecting flange and the flange connecting plate are connected by screws, and the flange connecting plate is connected to the top of the linear module by screws; the bottom end of the slider on the linear module lead screw is fixed to the connecting plate by screws.

[0012] Furthermore, the linear module serves as an auxiliary motion mechanism connecting the robot and the end effector. When the robot drives the linear module slide to move forward at a certain speed v, the servo motor of the linear module drives the lead screw to rotate in the opposite direction, causing the slider to drive the end effector sewing mechanism to move in the opposite direction at a speed v. The two speeds are equal in magnitude but opposite in direction, so that the end effector sewing mechanism and the prefabricated fabric remain relatively stationary, achieving motion compensation.

[0013] Furthermore, magnetic switches are embedded and fixed with screws in the cylinder slots at the starting and ending points of the tufting cylinder and the presser foot cylinder. The tufting sewing end actuator uses compressed air as a power source to drive the piston rod of the tufting cylinder to reciprocate, thereby driving the yarn feeding rod to feed the yarn and driving the needle plate to reciprocate to achieve needle punching; the piston rod of the presser foot cylinder drives the presser foot to reciprocate to achieve a fixing effect.

[0014] Furthermore, the wire feeding rod and the needle plate are connected to the tufting cylinder by screws, the needle connector is connected to the needle plate by threads, and the needle is inserted into the needle connector by fitting; the presser foot cylinder is connected to the presser foot by screws; the pneumatic scissors are connected to the direct drive cylinder by threads, and the direct drive cylinder is fixed to the cylinder connecting plate by screws and connected to the connecting plate by screws.

[0015] Furthermore, the porcelain eye is specifically divided into a first porcelain eye, a second porcelain eye, a third porcelain eye, a fourth porcelain eye, a fifth porcelain eye, a sixth porcelain eye, and a seventh porcelain eye according to its location; the yarn passes through the first porcelain eye, the tension clamp, the second porcelain eye, the third porcelain eye, the fourth porcelain eye, the fifth porcelain eye, the breakage detection sensor, the sixth porcelain eye, and the seventh porcelain eye in sequence from the yarn tube, and finally passes through the needle; the porcelain eye is fixedly installed at the thread passage position of the connecting bracket by a tight fit.

[0016] Furthermore, a third ceramic eye is fixedly installed in the thread guide ring of the yarn feeding rod by a tight fit; a seventh ceramic eye is fixedly installed in the thread guide position of the needle plate by a tight fit; the bottom of the connecting bracket has an L-shaped composite structure, with a first ceramic eye installed at the end where the yarn is inserted, a second and a fourth ceramic eye installed on the protruding working parts on both sides of the yarn feeding rod, and a fifth and a sixth ceramic eye installed on the protruding working parts on both sides of the yarn breakage detection sensor.

[0017] Furthermore, the yarn clamp is spiral in shape, with a nut on the screw in the middle that can rotate, and the top of the spring fixed to the nut. By rotating the nut on the screw, the compression length of the spring can be changed, and the clamping force of the yarn clamp can be adjusted. When the yarn breaks, the clamping force of the yarn clamp spring can maintain the clamping state of the broken end.

[0018] Furthermore, the yarn tube and the yarn tube connecting plate are connected by threads, the yarn clamp is connected to the connecting bracket by threads, and the yarn breakage detection sensor is connected to the connecting bracket by screws.

[0019] Furthermore, the direct-drive cylinder is a rod-non-rotating cylinder, which ensures the linearity and consistency of the pneumatic scissors' movement trajectory and effectively reduces interference that may be caused by swaying.

[0020] Furthermore, the rotating table rotates according to a preset rotation speed and angle, enabling the complex irregular prefabricated fabric to be tufted and sewn while rotating; the combined core mold consists of a first combined core mold, a second combined core mold, a third combined core mold, and a fourth combined core mold connected one by one from top to bottom with screws; the combined foam base felt includes several foam base felts, each foam base felt corresponding to one module of the combined core mold.

[0021] A suturing method using the above-mentioned pneumatic tufting suturing robot includes the following steps:

[0022] S1, Install the combined core mold on the rotary table and check the reliability of the connection;

[0023] S2, install the modular foam base mats one by one on the surface of the modular core mold; lay the prefabricated fabric to be prepared on the surface of the modular foam base mat according to its thickness;

[0024] S3. The yarn is evenly wound onto the yarn tube and passed sequentially along the yarn feeding path through the following holes: the first hole (near the yarn tube end) on the connecting bracket, the tension clamp, the second hole (on the yarn feeding rod inlet side) on the connecting bracket, the third hole (on the yarn feeding rod through the yarn) on the connecting bracket, the fourth hole (on the yarn feeding rod outlet side) on the connecting bracket, the fifth hole (on the yarn breakage detection sensor inlet side) on the connecting bracket, the yarn breakage detection sensor, the sixth hole (on the yarn breakage detection sensor outlet side) on the connecting bracket, the seventh hole (on the needle plate through the yarn) on the connecting bracket, and finally into the needle.

[0025] S4, power on the equipment. The six-degree-of-freedom robot drives the tufting sewing end effector to move to the pre-sewing point according to the set program for sewing. During the process, the linear module drives the robot to move continuously without frequent start and stop, and real-time accurate monitoring is achieved through the detection switch of the lead screw slide. The presser foot cylinder and the tufting cylinder work together. First, the presser foot cylinder outputs its piston rod to push the presser foot downward, pressing the fabric. Then, the tufting cylinder outputs its piston rod to push the needle plate and needle downward, and the needle pierces the pre-made fabric. After the piston rod reaches the end point, the cylinder reverses, and the piston rod returns to the initial point. The needle and presser foot are lifted in sequence to complete one needle-punching cycle. During the yarn feeding process, the yarn breakage detection sensor monitors the yarn status in real time and promptly detects and reports any yarn breakage problems.

[0026] S5, the six-degree-of-freedom robot drives the tufting sewing end effector to move to the next sewing position, and the rotary table drives the combined mandrel to complete the feed at the predetermined angle and continue the needle suturing;

[0027] S6. Repeat steps S4-S5 until the sewing of the prefabricated fabric is completed. The output of the direct drive cylinder pushes the pneumatic scissors to move in a straight line. The output of the pneumatic scissors' cylinder cuts the yarn. After completion, the direct drive cylinder drives the pneumatic scissors back to the initial position.

[0028] S7, the six-degree-of-freedom robot drives the tufting stitching end effector back to the target stopping position.

[0029] The advantages and positive effects of this invention are as follows:

[0030] 1. The tufting action of the present invention adopts a pneumatic actuator, which has a simple structure and low cost; the stroke of the tufting cylinder is adjustable, which facilitates the rapid adjustment of the tufting sewing depth; both the tufting cylinder and the presser foot cylinder adopt a three-axis guided structure, which ensures smooth movement and high precision, and is suitable for tufting sewing of complex irregular prefabricated fabrics.

[0031] 2. This invention integrates an active yarn feeding function. The return motion of the tufting cylinder drives the yarn feeding rod to move, thereby realizing active traction and quantitative yarn feeding. The structure is simple and the yarn feeding length is precisely controllable, which improves the stability and quality of the sewing process.

[0032] 3. This invention integrates a yarn breakage detection function. By using a yarn breakage detection sensor to monitor the yarn status in real time, it can promptly detect yarn breakage problems and provide feedback, ensuring the continuity and stability of the production process.

[0033] 4. This invention integrates tension control function, which can stabilize yarn tension by adjusting the clamping force of the thread clamp; the thread clamp can be flexibly adjusted for preforms of different thicknesses and densities as well as different sewing yarns to ensure tension matching and improve the uniformity of finished products; at the same time, if the yarn breaks, the thread clamp can clamp the broken end to prevent the entire yarn from coming out of the yarn feeding path, shortening maintenance time and reducing material waste.

[0034] 5. This invention uses ceramic eyelets as a key yarn guiding component in the yarn feeding path, which can significantly reduce the coefficient of friction between the yarn and the yarn guide ring, avoiding yarn fuzzing, breakage, or wear. Especially for brittle materials or fast-moving yarns, ceramic eyelets can reduce mechanical damage and maintain the original strength and elasticity of the yarn. At the same time, the use of smooth ceramic eyelets in conjunction with components such as yarn clamps helps to maintain the stability of yarn tension and reduce tension abnormalities caused by fluctuations in the coefficient of friction.

[0035] 6. This invention integrates motion compensation functionality, using a linear module as an auxiliary motion mechanism to connect the robot and the end effector. This enables the continuous movement of the robot and the parallel action of the end effector's sewing mechanism during the tufting sewing process. The robot drives the linear module slide table forward at a certain speed v, while the linear module screw rotates in the opposite direction, causing the slider to drive the end effector's sewing mechanism to move in the opposite direction at speed v. This keeps the end effector's sewing mechanism and the prefabricated fabric relatively stationary, completing the presser foot movement and tufting sewing movement, thus ensuring the quality of the sewing. The robot moves continuously without frequent starts and stops, significantly improving production efficiency and avoiding needle breakage.

[0036] 7. This invention uses a cylinder with a non-rotating piston rod as the driving element for the linear motion of the pneumatic scissors. The cylinder piston rod moves only along the axial direction, which ensures that the cutting action of the pneumatic scissors is more accurate and reduces the cutting deviation caused by rotation.

[0037] 8. The present invention is equipped with a magnetic switch for the piston rod cylinder, which can synchronously feedback the stroke status of each cylinder, provide a precise position signal, and then adjust the reciprocating speed of the cylinder to meet the requirements of tufting sewing speed for sewing yarns of different toughness.

[0038] 9. The present invention is equipped with a seventh-axis rotary table, which drives the fabric to rotate in real time, and can meet the requirements of tufting and sewing complex irregular prefabricated fabrics while rotating.

[0039] 10. The present invention is equipped with a modular core mold, and each module of the core mold can be disassembled and assembled separately, which facilitates the demolding of large-sized tufted sewn prefabricated components and makes them easy to disassemble and replace. Attached Figure Description

[0040] Figure 1 This is a schematic diagram of the overall structure of the device according to an embodiment of the present invention;

[0041] Figure 2 This is a schematic diagram of the linear module structure in one embodiment of the present invention;

[0042] Figure 3 This is a right-view stereoscopic structural diagram of an embodiment of the present invention;

[0043] Figure 4 This is a schematic diagram of the right-side structure of an embodiment of the present invention;

[0044] Figure 5 This is a front view structural diagram of an embodiment of the present invention;

[0045] Figure 6 This is a rear-view stereoscopic structural diagram of an embodiment of the present invention;

[0046] Figure 7 This is a schematic diagram of the left-side stereoscopic structure of an embodiment of the present invention;

[0047] Figure 8 This is a schematic diagram of a portion of the yarn feeding mechanism according to an embodiment of the present invention;

[0048] Figure 9 This is a schematic diagram of the rotary table device in one embodiment of the present invention;

[0049] Figure 10 This is a three-dimensional disassembly diagram of a combined core mold in one embodiment of the present invention;

[0050] Figure 11 This is a cross-sectional structural diagram of a combined core mold in one embodiment of the present invention;

[0051] In the diagram, 1-Tufting sewing end effector; 2-Six-DOF robot; 3-Robot base; 4-Rotary worktable; 5-Robot connecting flange; 6-Linear module; 7-Connecting plate; 8-Needle connector; 9-Needle plate; 10-Thread feed rod; 11-Connecting bracket; 12-Tufting cylinder; 13-Yarn tube connecting plate; 14-Thread clamp; 15-Yarn tube; 16-Pressure foot; 17-Needle; 18-Pneumatic scissors; 19-Direct drive cylinder; 20-Cylinder connecting plate; 21-Cylinder magnetic switch;

[0052] 22-Porcelain eye; 23-Thread breakage detection sensor; 24-Yarn; 25-Pressure foot cylinder; 26-Reinforcing rib; 27-Flange connecting plate; 28-Detection switch; 29-Combined core mold; 30-Rotating table; 31-Workbench; 32-Precast fabric; 33-Combined foam base felt; 34-First combined core mold; 35-Second combined core mold; 36-Third combined core mold; 37-Fourth combined core mold; 38-Core mold mounting base; 39-First porcelain eye; 40-Second porcelain eye; 41-Third porcelain eye; 42-Fourth porcelain eye; 43-Fifth porcelain eye; 44-Sixth porcelain eye; 45-Seventh porcelain eye. Detailed Implementation

[0053] To further disclose the invention's content, features, and effects, the following examples are provided in conjunction with the accompanying drawings for detailed explanation. In the following description of the embodiments, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings. They are used solely for the convenience of describing this patent and for simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this patent.

[0054] In the following description of the embodiments, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "setting" should be interpreted broadly. For example, they can refer to a fixed connection or setting, a detachable connection or setting, or an integral connection or setting. Those skilled in the art can understand the specific meaning of the above terms in this patent according to the specific circumstances.

[0055] Example: See Appendix Figure 1-11 A pneumatic tufting sewing robot includes a six-degree-of-freedom robot 2, a tufting sewing end effector 1, and a rotary table 4; the end of the robotic arm of the six-degree-of-freedom robot 2 is connected to the tufting sewing end effector 1 and controls it to sew a prefabricated fabric 32 set on the rotary table 4; the tufting sewing end effector 1 includes a displacement mechanism, a needle punching mechanism, a presser foot mechanism, a yarn feeding mechanism, and a pneumatic shearing mechanism;

[0056] like Figures 2-3As shown, the displacement mechanism includes a robot connecting flange 5, a linear module 6, and a detection switch 28. The robot connecting flange 5 is fixed to and mounted on the linear module 6 with a flange connecting plate 27. The robot connecting flange 5 can slide relative to the lead screw of the linear module 6. The detection switch 28 is located at both ends of the lead screw slide of the linear module 6. The linear module 6 serves as an auxiliary motion mechanism connecting the six-degree-of-freedom robot 2 and the tufting sewing end effector 1. A connecting plate 7 is installed in the middle of the linear module 6, and a needle-punching mechanism is provided at the other end of the connecting plate 7. The robot connecting flange 5 and the flange connecting plate 27 are connected by screws, and the flange connecting plate 27 is connected to the linear module 6 by screws. The linear module 6 is fixed to the connecting plate 7 by screws. The detection switch 28 is installed at the starting and ending points of the lead screw slide by screws. The connecting plate 7 is L-shaped, and a reinforcing rib 26 is fixed to the middle of the inner side of the right angle of the L-shape by screws to improve the overall strength and enhance the resistance to deformation.

[0057] like Figure 4 As shown, the needle-punching mechanism includes a tufting cylinder 12, a wire feeding rod 10, a needle plate 9, and a needle 17. The tufting cylinder 12 is installed on one side of the connecting plate 7. The needle plate 9 is provided at the bottom of the tufting cylinder 12, and the wire feeding rod 10 is provided on the side. The needle 17 is installed at the bottom of the needle plate 9 through a needle connector 8. The wire feeding rod 10 and the needle plate 9 are connected to the tufting cylinder 12 by screws. The needle connector 8 is connected to the needle plate 9 by threads, and the needle 17 is inserted into the needle connector 8 through a mating fit.

[0058] like Figures 4-8 As shown, the presser foot mechanism includes a presser foot cylinder 25 and a presser foot 16. The presser foot cylinder 25 is installed on the other side of the connecting plate 7, and its bottom is connected to the presser foot 16 by screws. The base plate of the presser foot 16 is located below the needle 17. The piston rod of the presser foot cylinder 25 pushes the presser foot 16 to reciprocate for fixation. The piston rod of the tufting cylinder 12 reciprocates, thereby driving the yarn feeding rod 10 to feed yarn and driving the needle plate 9 to reciprocate for needle punching. Magnetic switches 21 are embedded in the cylinder grooves at the starting and ending points of the tufting cylinder 25 and the presser foot cylinder 12 and fixed with screws. The tufting sewing end actuator 1 uses compressed air as a power source to drive the piston rod of the tufting cylinder 12 to reciprocate, thereby driving the yarn feeding rod 10 to feed yarn and driving the needle plate 9 to reciprocate for needle punching. The piston rod of the presser foot cylinder 25 pushes the presser foot 16 to reciprocate for fixation.

[0059] like Figures 4-8As shown, a cylinder connecting plate 20 is installed on one end face of the connecting plate 7, and a yarn tube connecting plate 13 and a connecting bracket 11 are installed on the other end face. The three are located on both sides of the tufting cylinder 12 and the presser foot cylinder 25. The yarn feeding mechanism includes a yarn tube 15, a yarn clamp 14, and a yarn breakage detection sensor 23. The yarn tube 15 is installed on the yarn tube connecting plate 13. The connecting bracket 11 has a yarn clamp 14 installed at one end near the yarn tube 15, a yarn feeding top rod 10 inserted in the middle, and a yarn breakage detection sensor 23 installed at the end near the tufting cylinder 12. The yarn detection sensor 23, connecting bracket 11, yarn feeding rod 10, and needle plate 9 are equipped with ceramic eyes 22. These ceramic eyes 22 are specifically divided into first ceramic eyes 39, second ceramic eyes 40, third ceramic eyes 41, fourth ceramic eyes 42, fifth ceramic eyes 43, sixth ceramic eyes 44, and seventh ceramic eyes 45, depending on their position. The yarn tube 15 is threadedly connected to the yarn tube connecting plate 13, the yarn clamp 14 is threadedly connected to the connecting bracket 11, and the yarn breakage detection sensor 23 is screwed to the connecting bracket 11. The third ceramic eye 41 is fixedly installed in the yarn guide ring of the yarn feeding rod 10 through a tight fit; the seventh ceramic eye 45 is fixedly installed at the yarn guide position of the needle plate 9 through a tight fit. The bottom of the connecting bracket 11 has an L-shaped composite structure, and the upper part of the connecting bracket 11 is a mounting rod with a through groove for easy fixing to the end face of the connecting plate 7. The ceramic eyes 22 installed at the yarn guide position of the connecting bracket 11 are fixed through a tight fit. The connecting bracket 11 has a first ceramic eye 39 installed at the end where the yarn 24 is inserted (i.e., the end near the yarn tube 15), a second ceramic eye 40 and a fourth ceramic eye 42 installed on the protruding working parts located on both sides of the yarn feeding rod 10, and a fifth ceramic eye 43 and a sixth ceramic eye 44 installed on the protruding working parts located on both sides of the yarn breakage detection sensor 23. The yarn 24 passes sequentially from the yarn tube 15 through the first ceramic eye 39, the tension clamp 14, the second ceramic eye 40, the third ceramic eye 41, the fourth ceramic eye 42, the fifth ceramic eye 43, the yarn breakage detection sensor 23, the sixth ceramic eye 44, and the seventh ceramic eye 45, and finally passes into the needle 17. The yarn clamp 14 is spiral in shape, with a nut on the screw in the middle that can rotate and the top of the spring fixed to the nut. By rotating the nut on the screw, the compression length of the spring can be changed, and the clamping force of the yarn clamp 14 can be adjusted. When the yarn 24 breaks, the clamping force of the spring in the yarn clamp 14 can maintain the clamping state of the broken end.

[0060] like Figures 4-8 As shown, the pneumatic shear mechanism includes pneumatic shears 18 and a direct-drive cylinder 19. The direct-drive cylinder 19 is fixedly mounted on the cylinder connecting plate 20, and the pneumatic shears 18 is installed at the working end of the direct-drive cylinder 19. The pneumatic shears 18 and the direct-drive cylinder 19 are connected by threads, and the direct-drive cylinder 19 is fixed to the cylinder connecting plate 20 by screws and connected to the connecting plate 7 by screws. The direct-drive cylinder 19 is a rod-non-rotating cylinder to ensure the linearity and consistency of the movement trajectory of the pneumatic shears 18, effectively reducing interference that may be caused by swaying.

[0061] like Figure 9-11 As shown, the rotary worktable 4 includes a combined core mold 29, a core mold mounting base, a rotary table, and a worktable. A rotary table is mounted on the worktable, and a core mold mounting base is fixedly mounted on the rotary table. The core mold mounting base connects to the combined core mold, and a combined foam base felt 33 is mounted on the surface of the combined core mold 29. The rotary table 30 rotates according to a preset rotation speed and angle, enabling the complex irregularly shaped prefabricated fabric 32 to be tufted and sewn while rotating. The combined core mold 29 is composed of a first combined core mold 34, a second combined core mold 35, a third combined core mold 36, and a fourth combined core mold 37, connected one by one with screws. The combined foam base felt 33 includes several foam base felts, each corresponding to a module of the combined core mold 29.

[0062] The robot in this example uses a pneumatic end effector with a simple mechanical structure. It integrates an adjustable-stroke, guided cylinder, allowing for easy adjustment of the tufting and sewing depth, and stable control over the orientation of the sewing needle 17. It is equipped with yarn tension control and yarn breakage detection functions, effectively controlling the forming quality and providing yarn breakage alarms. Simultaneously, it integrates tufting motion compensation, enabling continuous movement during the robot's tufting and sewing process without frequent starts and stops, significantly improving sewing efficiency. Furthermore, it is equipped with a 7th-axis rotary table 4, which allows for the simultaneous tufting and sewing of complex, irregularly shaped prefabricated fabrics 32 while they rotate.

[0063] A suturing method using the above-mentioned pneumatic tufting suturing robot includes the following steps:

[0064] S1, install the combined core mold 29 (specifically, the first combined core mold 34, the second combined core mold 35, the third combined core mold 36 and the fourth combined core mold 37 are connected one by one with screws from top to bottom) on the rotary table 4 and check the reliability of the connection;

[0065] S2, install the modular foam base mat 33 one by one on the surface of the modular core mold 29; lay the prefabricated fabric 32 to be prepared on the surface of the modular foam base mat 33 according to its thickness;

[0066] S3, the yarn 24 is evenly wound around the yarn tube 15 and passes through the following holes along the yarn feeding path: the first hole 39 (also known as the first ceramic eye) on the connecting bracket 11 near the yarn tube 15, the tension clamp 14, the second hole 40 (also known as the second ceramic eye) on the connecting bracket 11 on the side where the yarn feed rod 10 enters, the third hole 41 (also known as the third ceramic eye) on the yarn feed rod 10, the fourth hole 42 (also known as the fourth ceramic eye) on the connecting bracket 11 on the side where the yarn feed rod 10 exits, the fifth hole 43 (also known as the fifth ceramic eye) on the connecting bracket 11 on the side where the yarn breakage detection sensor 23 enters, the yarn breakage detection sensor 23, the sixth hole 44 (also known as the sixth ceramic eye) on the connecting bracket 11 on the side where the yarn breakage detection sensor 23 exits, the seventh hole 45 (also known as the seventh ceramic eye) on the needle plate 9, and finally into the needle 17.

[0067] S4, power on the equipment. The six-degree-of-freedom robot 2 drives the tufting sewing end effector 1 to move to the pre-sewing point for sewing according to the set program. During the process, the linear module 6 drives the robot to move continuously without frequent start and stop, and real-time accurate monitoring is performed through the detection switch 28 of the lead screw slide. The presser foot cylinder 25 and the tufting cylinder 12 cooperate with each other. First, the presser foot cylinder 25 outputs its piston rod to push the presser foot 16 downward, and the presser foot 16 presses the fabric. Then, the tufting cylinder 12 outputs its piston rod to push the needle plate 9 and the needle 17 downward. The needle 17 pierces the pre-made fabric 32. After the piston rod reaches the end point, the cylinder reverses and the piston rod returns to the initial point. The needle 17 and the presser foot 16 lift up in sequence to realize one needle-punching cycle. During the yarn feeding process, the yarn breakage detection sensor 23 monitors the yarn status in real time and promptly detects and reports any yarn breakage problems.

[0068] S5, the six-degree-of-freedom robot 2 drives the tufting sewing end effector 1 to move to the next sewing position, and the rotary table 4 drives the combined core mold 29 to complete the feed at the predetermined angle and continue the needle suturing.

[0069] S6. Repeat steps S4-S5 until the sewing of the prefabricated fabric 32 is completed. The output of the direct drive cylinder 19 pushes the pneumatic scissors 18 to move in a straight line. The cylinder output of the pneumatic scissors 18 cuts the yarn 24. After completion, the direct drive cylinder 19 drives the pneumatic scissors 18 back to the initial position.

[0070] S7, the six-degree-of-freedom robot 2 drives the tufting sewing end effector 1 back to the target stopping position.

[0071] Although preferred embodiments of the present invention have been described above, the present invention is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art, under the guidance of the present invention, can make many other modifications without departing from the spirit and scope of the claims. These modifications all fall within the scope of protection of the present invention.

Claims

1. A pneumatic tufting sewing robot, characterized in that: It includes a six-degree-of-freedom robot (2), a tufting sewing end effector (1), and a rotary table (4); the end of the robotic arm of the six-degree-of-freedom robot (2) is connected to the tufting sewing end effector (1) and controls it to sew the prefabricated fabric (32) set on the rotary table (4); the tufting sewing end effector (1) includes a displacement mechanism, a needle punching mechanism, a presser foot mechanism, a yarn feeding mechanism, and a pneumatic shearing mechanism; The displacement mechanism includes a robot connecting flange (5), a linear module (6), and a detection switch (28). The robot connecting flange (5) is fixed to the flange connecting plate (27) and installed on the linear module (6). The robot connecting flange (5) can slide relative to the lead screw of the linear module (6). The detection switch (28) is set at both ends of the lead screw slide of the linear module (6). A connecting plate (7) is installed in the middle of the linear module (6). A needle-punching mechanism is set at the other end of the connecting plate (7). The needle-punching mechanism includes a tufting cylinder (12), a wire feeding rod (10), a needle plate (9), and a needle (17). The tufting cylinder (12) is installed on one side of the connecting plate (7). The bottom of the tufting cylinder (12) is provided with a needle plate (9) and the side is provided with a wire feeding rod (10). The needle (17) is installed at the bottom of the needle plate (9) through a needle connector (8). The presser foot mechanism includes a presser foot cylinder (25) and a presser foot (16). The presser foot cylinder (25) is installed on the other side of the connecting plate (7). The presser foot (16) is provided at the bottom of the presser foot cylinder (25). The bottom plate of the presser foot (16) is located below the needle (17). The piston rod of the presser foot cylinder (25) pushes the presser foot (16) to reciprocate to achieve fixation. The piston rod of the tufting cylinder (12) reciprocates to drive the yarn feeding rod (10) to achieve yarn feeding, and drives the needle plate (9) to reciprocate to achieve needle punching. One end face of the connecting plate (7) is equipped with a cylinder connecting plate (20), and the other end face is equipped with a yarn tube connecting plate (13) and a connecting bracket (11); the yarn feeding mechanism includes a yarn tube (15), a yarn clamp (14), and a yarn breakage detection sensor (23). The yarn tube is installed on the yarn tube connecting plate (13). The connecting bracket (11) is equipped with a yarn clamp (14) at one end near the yarn tube (15), a yarn feeding rod (10) is inserted in the middle, and a yarn breakage detection sensor (23) is installed at one end near the tufting cylinder (12). The connecting bracket (11), the yarn feeding rod (10), and the needle plate (9) are provided with ceramic eyes (22). The pneumatic shear mechanism includes a pneumatic shear (18) and a direct-drive cylinder (19). The direct-drive cylinder (19) is fixedly mounted on the cylinder connecting plate (20), and the pneumatic shear (18) is installed at the working end of the direct-drive cylinder (19). The rotary worktable (4) includes a combined core mold (29), a core mold mounting base (38), a rotary table (30), and a worktable (31); the worktable (31) is provided with a rotary table (30), the rotary table (30) is fixedly mounted with a core mold mounting base (38), the core mold mounting base (38) is connected to the combined core mold (29), and the surface of the combined core mold (29) is covered with a combined foam base felt (33).

2. The pneumatic tufting and sewing robot according to claim 1, characterized in that: The detection switch (28) is installed at the starting point and the ending point of the lead screw slide by screws respectively; the connecting plate (7) is L-shaped in general, and the middle of the inner side of the right angle of the L-shape is fixed with a reinforcing rib (26) by screws.

3. The pneumatic tufting and sewing robot according to claim 1, characterized in that: The magnetic switches (21) are embedded in the cylinder slots at the starting and ending points of the tufting cylinder (12) and the presser foot cylinder (25) and fixed with screws.

4. The pneumatic tufting sewing robot according to claim 1, characterized in that: The porcelain eye (22) is specifically divided into the first porcelain eye (39), the second porcelain eye (40), the third porcelain eye (41), the fourth porcelain eye (42), the fifth porcelain eye (43), the sixth porcelain eye (44), and the seventh porcelain eye (45) according to its location; the porcelain eye (22) is fixedly installed at the wire passage position of the connecting bracket (11) by tight fit.

5. A pneumatic tufting and sewing robot according to claim 4, characterized in that: The third ceramic eye (41) is fixedly installed in the thread guide ring of the yarn feeding rod (10) by a tight fit, and the seventh ceramic eye (45) is fixedly installed in the thread guide position of the needle plate (9) by a tight fit; the bottom of the connecting bracket (11) has an L-shaped composite structure, the first ceramic eye (39) is installed at the end where the yarn (24) is connected, the second ceramic eye (40) and the fourth ceramic eye (42) are respectively installed on the protruding working parts on both sides of the yarn feeding rod (10), and the fifth ceramic eye (43) and the sixth ceramic eye (44) are respectively installed on the protruding working parts on both sides of the broken thread detection sensor (23).

6. A pneumatic tufting and sewing robot according to claim 1, characterized in that: The wire clamp (14) is spiral in shape, and the nut on the screw in the middle can rotate. The top of the spring is fixed to the nut. By rotating the nut on the screw, the clamping force of the wire clamp (14) can be adjusted by changing the compression length of the spring.

7. A pneumatic tufting and sewing robot according to claim 1, characterized in that: The yarn tube (15) is connected to the yarn tube connecting plate (13) by threads, the wire clamp (14) is connected to the connecting bracket (11) by threads, and the broken wire detection sensor (23) is connected to the connecting bracket (11) by screws.

8. A pneumatic tufting and sewing robot according to claim 1, characterized in that: The direct-drive cylinder (19) is a rod-non-rotating cylinder.

9. A pneumatic tufting sewing robot according to claim 1, characterized in that: The rotating table (30) rotates according to a preset rotation speed and angle; the combined core mold (29) is composed of a first combined core mold (34), a second combined core mold (35), a third combined core mold (36), and a fourth combined core mold (37) connected one by one from top to bottom with screws; the combined foam base felt (33) includes several foam base felts, each foam base felt corresponding to a module of the combined core mold (29).

10. A sewing method using a pneumatic tufting sewing robot as described in any one of claims 1-9, characterized in that, Includes the following steps: S1, install the combined core mold (29) on the rotary table (4); S2, install the composite foam base mat (33) one by one on the surface of the composite core mold (29); lay the prefabricated fabric (32) to be prepared on the surface of the composite foam base mat (33) according to its thickness; S3, the yarn (24) is evenly wound on the yarn tube (15) and passed through the following holes along the yarn feeding path: the ceramic eye (22) on the connecting bracket (11) near the yarn tube (15), the tension clamp (14), the ceramic eye (22) on the connecting bracket (11) on the side where the yarn feed rod (10) enters, the ceramic eye (22) at the yarn feeding rod (10) passing through the yarn, the ceramic eye (22) on the connecting bracket (11) on the side where the yarn feed rod (10) exits, the ceramic eye (22) on the connecting bracket (11) on the side where the yarn breakage detection sensor (23) enters, the yarn breakage detection sensor (23), the ceramic eye (22) on the connecting bracket (11) on the side where the yarn breakage detection sensor (23) exits, the ceramic eye (22) at the yarn feeding position of the needle plate (9), and finally inserted into the needle (17). S4, start the equipment. The six-degree-of-freedom robot (2) drives the tufting sewing end actuator (1) to move to the pre-sewing point for sewing according to the set program. During the process, the linear module (6) drives the robot to move continuously and monitors it in real time through the detection switch (28) of the screw slide. The presser foot cylinder (25) and the tufting cylinder (12) cooperate with each other. First, the presser foot cylinder (25) outputs its piston rod to push the presser foot (16) downward. The presser foot (16) presses the fabric tightly. Then, the tufting cylinder (12) outputs its piston rod to push the needle plate (9) and the needle (17) downward. The needle (17) pierces the pre-made fabric (32). After the piston rod reaches the end point, the cylinder reverses and the piston rod returns to the initial point. The needle (17) and the presser foot (16) lift up in sequence to realize one needle-punching cycle. During the yarn feeding process, the yarn breakage detection sensor (23) monitors the yarn (24) status in real time and promptly detects and reports yarn breakage problems. S5, the six-degree-of-freedom robot (2) drives the tufting sewing end actuator (1) to move to the next sewing position, and the rotary table (4) drives the combined core mold (29) to complete the feed at the predetermined angle and continue the needle suturing; S6. Repeat steps S4-S5 until the sewing of the prefabricated fabric (32) is completed. The output of the direct drive cylinder (19) pushes the pneumatic scissors (18) to move in a straight line. The cylinder output of the pneumatic scissors (18) cuts the yarn (24). After completion, the direct drive cylinder (19) drives the pneumatic scissors (18) back to the initial position. S7, the six-degree-of-freedom robot (2) drives the tufting stitching end effector (1) back to the target stopping position.

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