Process for sewing internal parts of automatic cutting bed machine

Abstract

The invention belongs to the technical field of automatic cutting bed machines, and particularly relates to a process for sewing internal parts of an automatic cutting bed machine, which comprises the following steps: a part positioning and pretreatment step, a sewing line planning step, a sewing equipment adjustment step, a sewing execution step and a quality detection and repair step. The sewing precision can be improved, and the stability of product quality is guaranteed; the sewing efficiency is remarkably improved, the production cycle is shortened, and the large-scale production requirement is met; meanwhile, the sewing machine is suitable for sewing internal parts made of various materials, and especially the sewing effect on special materials can be improved.

Description

Technical Field

[0001] The invention belongs to the technical field of automatic cutting machines, and in particular relates to a process for sewing internal components of an automatic cutting machine. Background Art

[0002] Automatic cutting machines occupy a vital position in modern manufacturing, widely used in a variety of fields, including garment processing, automotive interior production, and furniture manufacturing. Within this sector, automatic cutting machines undertake the crucial tasks of fabric cutting and component stitching, encompassing the production of a wide range of garments, including shirts, trousers, and jackets. Garment components, such as collars, cuffs, and pockets, are diverse in material, including cotton, linen, silk, synthetic fibers, and various blends. The designs are complex and varied, placing extremely high demands on stitching precision and efficiency.

[0003] However, when existing automatic cutting machines are used, due to the complex and diverse shapes of the internal components, traditional sewing methods often cannot meet the high-precision requirements, resulting in unstable product quality. Summary of the Invention

[0004] The present invention aims to provide a process for sewing internal components of an automatic cutting machine to address the problems identified in the aforementioned background art. This process improves sewing precision, ensuring consistent product quality; significantly increases sewing efficiency, shortens production cycles, and meets the demands of large-scale production. Furthermore, it is adaptable to sewing internal components made of various materials, particularly improving the sewing effect on special materials.

[0005] To achieve the above object, the technical solution adopted by the present invention is to provide a process for sewing internal components of an automatic cutting machine, comprising the following steps:

[0006] Parts positioning and pre-processing steps: Use a high-precision visual recognition system to identify and locate the internal parts placed on the workbench of the automatic cutting machine, obtain the precise position and posture information of the parts, and pre-process the parts through a vacuum adsorption device and a mechanical leveling device;

[0007] Suture line planning step: Based on the shape, size and design requirements of the internal components, an optimized path planning algorithm is used to generate the suture line trajectory in the computer control system;

[0008] Suturing device adjustment step: automatically adjusting parameters of the suturing device according to the suture line planning results and the material and thickness of the internal components, the parameters including the type of suture needle, thread tension and suturing speed;

[0009] Suture execution steps: start the sewing device of the automatic cutting machine and sew according to the preset sewing line trajectory and adjusted parameters;

[0010] Quality inspection and repair steps: After suturing is completed, the sutured area is inspected for quality using a non-destructive testing device, and defects detected in the components are repaired using an automated repair device.

[0011] Optionally, the high-precision visual recognition system uses multiple cameras, which are distributed around and above the workbench of the automatic cutting machine to form an all-round shooting angle. The camera frame rate is 30 frames per second, which can capture the dynamic changes of components in real time, ensuring effective identification and positioning during the component placement process.

[0012] Optionally, in the component positioning and pretreatment steps, the adsorption pressure of the vacuum adsorption device is adjusted according to the material of the component. For softer fabric materials, the adsorption pressure is set to 0.03-0.05MPa; for harder leather materials, the adsorption pressure is set to 0.06-0.08MPa, to ensure that the component can be firmly adsorbed without causing damage to the component.

[0013] Optionally, the optimized path planning algorithm performs trajectory smoothing after generating the suture line trajectory, and smoothly transitions the turning points on the trajectory through Bezier curves, thereby reducing the impact and vibration of the suture needle during movement and improving the stability and accuracy of suture.

[0014] Optionally, an intelligent control system is used for adjustment in the suturing equipment adjustment step. The parameter library of the intelligent control system is updated regularly, and the parameters are optimized and supplemented by collecting suturing data and quality feedback during the actual production process to adapt to the ever-changing materials and production requirements.

[0015] Optionally, in the suturing execution step, sensors are used to monitor the suturing status in real time, and the sensors include force sensors, displacement sensors and image sensors.

[0016] Optionally, the nondestructive testing device includes an ultrasonic testing device and a visual testing device, wherein the ultrasonic testing device detects defects within a depth of 2 mm inside the sutured part with a detection accuracy of ±0.2 mm; the visual testing device analyzes the image of the sutured part through a deep learning algorithm to accurately identify uneven stitch length and leaking seam defects.

[0017] Optionally, the automated repair device includes an automatic seam-filling mechanism and a suture thread adjustment mechanism. The automatic seam-filling mechanism automatically adjusts the position of the suture needle to repair the seam according to the detected leak position; the suture thread adjustment mechanism repairs the parts with uneven needle spacing or inappropriate thread tension by adjusting the thread delivery amount and tension.

[0018] Compared with the prior art, the present invention has the following beneficial effects:

[0019] 1. This invention utilizes a high-precision visual recognition system and real-time sensor monitoring to accurately identify and locate internal components and precisely control the suturing process. The high-precision visual recognition system ensures accurate positioning of components before suturing; the sensor, with a sampling frequency of 1000Hz, can promptly capture subtle changes during the suturing process, achieving a suturing accuracy of ±0.1mm and significantly improving product quality stability.

[0020] 2. The present invention adopts an optimized path planning algorithm and an intelligent control system. The optimized path planning algorithm combines the idea of ​​dynamic planning to give priority to the optimal path, thereby reducing unnecessary movement; the intelligent control system can quickly match and adjust parameters from the parameter library, shortening the equipment adjustment time; at the same time, the parameter library of the intelligent control system stores a large number of suturing parameters corresponding to different materials and thicknesses, and can be updated regularly. For special materials such as elastic materials, multi-layer composite materials, etc., good suturing effects can also be achieved through precise adjustment of parameters.

[0021] 3. The present invention adopts non-destructive testing equipment and automated repair equipment to timely detect and repair defects in the suturing process; the combination of ultrasonic testing and visual inspection can comprehensively detect internal and surface quality problems of the sutured parts with high detection precision and accuracy; the automated repair equipment can carry out targeted repairs on different types of defects, ensuring the overall quality of the product. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0023] Figure 1 Flowchart of the present invention. DETAILED DESCRIPTION

[0024] In order to make the technical problems, technical solutions and beneficial effects to be solved by the present invention more clearly understood, the present invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0025] Reference Figure 1 Now, a process for sewing internal components of an automatic cutting machine provided by an embodiment of the present invention is described.

[0026] A process for sewing internal components of an automatic cutting machine, comprising the following steps:

[0027] Component positioning and preprocessing steps: Use a high-precision visual recognition system to identify and locate internal components placed on the workbench of the automatic cutting machine, obtain the precise position and posture information of the components, and preprocess the components through a vacuum adsorption device and a mechanical leveling device; the high-precision visual recognition system uses multiple cameras, and multiple cameras are distributed around and above the workbench of the automatic cutting machine to form an all-round shooting angle. The camera frame rate is 30 frames / second, which can capture the dynamic changes of components in real time to ensure effective identification and positioning during the component placement process; in the component positioning and preprocessing steps, the adsorption pressure of the vacuum adsorption device is adjusted according to the material of the component. For softer fabric materials, the adsorption pressure is set to 0.03-0.05MPa; for harder leather materials, the adsorption pressure is set to 0.06-0.08MPa to ensure that the components can be firmly adsorbed without causing damage to the components.

[0028] Specifically, this high-precision visual recognition system uses a multi-camera, multi-angle shooting method, capable of quickly and accurately identifying the edges and feature points of internal components against complex backgrounds, with an identification accuracy of ±0.1mm. Components with uneven surfaces or wrinkles are pre-processed using a vacuum adsorption device and a mechanical leveling device. The vacuum adsorption device generates negative pressure through evenly distributed adsorption holes, firmly adsorbing the component to the workbench to prevent displacement during pre-processing and subsequent stitching. The mechanical leveling device includes a pressure-adjustable leveling roller and a drive mechanism. The leveling roller can automatically adjust the pressure according to the material and thickness of the component. Driven by the drive mechanism, it rolls along the surface of the component, smoothing out wrinkles and ensuring a flat surface for subsequent stitching. For example, during the stitching process of a garment pocket, the visual recognition system accurately identifies the contours and mounting hole locations of the pocket component, then uses a vacuum adsorption device to adsorb the component, and then uses a mechanical leveling device to smooth out wrinkles, allowing the pocket component to maintain a stable posture during the stitching process.

[0029] Suture line planning steps: Based on the shape, size and design requirements of internal components, an optimized path planning algorithm is used to generate the suture line trajectory in the computer control system; after generating the suture line trajectory, the optimized path planning algorithm performs trajectory smoothing and uses Bezier curves to smoothly transition the turning points on the trajectory, reducing the impact and vibration of the suture needle during movement and improving the stability and accuracy of suture.

[0030] Specifically, the optimized path planning algorithm adopts an algorithm combined with the idea of ​​dynamic programming, taking into account the shortest path of the suture line while taking into account the process requirements of the suture process, such as avoiding frequent needle changes and large turning angles. Specifically, the algorithm first grids the three-dimensional model of the internal components and divides the surface of the component into multiple small grid units; then, according to the design requirements, the starting and end points of the suture are determined, and the optimal path is found between the grid units; in the path search process, the suture sequence, needle pitch, turning radius and other factors are comprehensively considered, and the path that can reduce the empty stroke and the number of needles is given priority to improve the suture efficiency. For example, for collar parts with complex shapes, the path planning algorithm will give priority to suture areas with large curvature changes, reasonably set the needle pitch, and reduce the number of needles while ensuring the suture strength, thereby speeding up the suture speed.

[0031] Suturing equipment adjustment steps: Automatically adjust the parameters of the suture equipment according to the suture line planning results and the material and thickness of the internal components. The parameters include the type of suture needle, thread tension and suture speed. The suture equipment adjustment steps are adjusted using an intelligent control system. The parameter library of the intelligent control system will be updated regularly. By collecting suture data and quality feedback from the actual production process, the parameters are optimized and supplemented to adapt to the ever-changing materials and production needs.

[0032] Specifically, this adjustment process is achieved through an intelligent control system. Based on information such as the material and thickness of internal components, the system selects the optimal parameters from a preset parameter library and achieves precise adjustment through motor drive and sensor feedback. The parameter library stores a large number of suturing parameters corresponding to different materials (such as leather, fabric, composite materials, etc.) and thicknesses, including the diameter, length, and tip shape of the suturing needle, and the material, diameter, tension range, and suturing speed range of the thread. By analyzing the material properties (such as hardness, elasticity, wear resistance, etc.) and thickness data of internal components, the intelligent control system matches the most suitable parameter combination from the parameter library, and uses servo motors to drive the relevant components of the suturing equipment to make adjustments. At the same time, sensors are used to monitor in real time whether the adjusted parameters meet the requirements, and any deviations are promptly corrected. For example, for internal parts made of leather with a thickness of 3mm, the intelligent control system selects a suture needle with a diameter of 0.8mm and a triangular needle tip, and high-strength polyester thread from the parameter library. The thread tension is set to 5-7N, and the suture speed is set to 1000-1200 stitches / minute. The installation position of the suture needle and the thread tension adjustment device are adjusted by the motor drive. The sensor monitors and feedbacks the adjustment results in real time to ensure that the parameters are accurate. For fabric materials, a suture needle with a diameter of 0.3mm and a round needle tip, soft cotton thread, the thread tension is set to 2-3N, and the suture speed is set to 1500-1800 stitches / minute to avoid damaging the fabric.

[0033] Suturing execution steps: start the sewing device of the automatic cutting machine and sew according to the preset sewing line trajectory and adjusted parameters; in the sewing execution step, sensors are used to monitor the sewing status in real time, and the sensors include force sensors, displacement sensors and image sensors.

[0034] Specifically, during the suturing process, sensors are used to monitor the suturing status in real time. These sensors include force sensors, displacement sensors, and image sensors. The force sensor monitors thread tension and the force between the needle and the component during suturing. With an accuracy of ±0.01N, it can promptly detect changes in thread tension and resistance to the needle. The displacement sensor monitors component displacement during suturing, with a measurement range of 0-50mm and an accuracy of ±0.001mm, preventing components from exceeding their permitted range of movement. The image sensor captures images of the sutured area in real time, with a resolution of 12 megapixels. It clearly captures details such as the needle's position, stitch shape, and arrangement, assisting in determining the suturing status. If an anomaly is detected, such as a thread break or component displacement, suturing is immediately stopped and an alarm is issued. The abnormal position and related data are recorded for subsequent analysis and processing. For example, a needle position sensor monitors the needle's position in real time to ensure it follows the predetermined trajectory. A tension sensor monitors thread tension. If the tension exceeds the set range, the tension adjustment device automatically adjusts to restore the thread tension to the normal range.

[0035] Quality inspection and repair steps: After suturing is completed, the sutured area is quality inspected using a non-destructive testing device, and defects detected in the components are repaired using an automated repair device. The non-destructive testing device includes ultrasonic testing equipment and visual testing equipment. The ultrasonic testing equipment detects defects within a depth of 2mm in the sutured area with a detection accuracy of ±0.2mm. The visual testing equipment uses a deep learning algorithm to analyze the image of the sutured area and accurately identify uneven stitch length and leaking seams. The automated repair device includes an automatic seam-filling mechanism and a suture thread adjustment mechanism. The automatic seam-filling mechanism automatically adjusts the position of the suture needle according to the detected leaking seam position for seam filling. For areas with uneven stitch length or inappropriate thread tension, the suture thread adjustment mechanism repairs them by adjusting the thread feed volume and tension.

[0036] Specifically, the ultrasonic inspection equipment includes an ultrasonic probe, a transmitting and receiving circuit, and a data processing system. The ultrasonic wave emitted by the ultrasonic probe passes through the suture site and is reflected when it encounters a defect. The reflected wave is received by the probe and converted into an electrical signal by the transmitting and receiving circuit. The data processing system analyzes the electrical signal to determine the location and size of the defect. The visual inspection system uses a high-definition camera to capture images of the suture site with a resolution of 20 million pixels. This image is then analyzed using a deep learning algorithm, accurately identifying surface defects such as uneven stitch length and leaky seams with an accuracy rate exceeding 98%. Detected defects are repaired using an automated repair device, which includes an automatic seam-filling mechanism and a suture-line adjustment mechanism. The automatic seam-filling mechanism automatically adjusts the position of the suture needle based on the detected leaky seam location, using the same parameters as the original suture line to ensure consistency between the repaired area and the surrounding suture lines. The suture-line adjustment mechanism can repair uneven stitch length or inappropriate thread tension by adjusting the thread feed rate and tension. For example, when the visual inspection system detects that the stitch length in a certain part is uneven, the suture thread adjustment mechanism will automatically adjust the thread delivery speed and tension according to the deviation to restore the stitch length to normal; when the ultrasound detects that there is an area inside the suture part that is not firmly sutured, the automatic seam repair mechanism will perform a second suture on the area to enhance the suture strength.

[0037] Example

[0038] Clothing pocket parts sewing

[0039] Component positioning and preprocessing: A garment pocket component, made of fabric with a thickness of 2mm, is placed on the workbench of the automatic cutting machine. The high-precision visual recognition system's multiple cameras capture the component from all sides and above at a frame rate of 30 frames per second, quickly and accurately identifying the component's edges and feature points with an accuracy of ±0.1mm. The vacuum adsorption device sets the adsorption pressure to 0.04MPa based on the fabric material, generating negative pressure through the adsorption holes to securely adsorb the component to the workbench. The mechanical leveling device's leveling rollers adjust the pressure to the appropriate value based on the fabric's thickness and softness. Driven by the drive mechanism, they roll along the component's surface, smoothing out wrinkles and ensuring a smooth surface.

[0040] Stitching Line Planning: Based on the shape and design requirements of the garment pocket, the computer control system uses an optimized path planning algorithm to generate the stitching trajectory. The 3D model of the garment pocket is first gridded, and the starting and ending points of the stitching are determined to be the edges of the garment pocket. The algorithm considers factors such as stitching sequence, stitch length, and turning radius when searching for the path. Edges with large changes in curvature are prioritized for stitching. A stitch length of 2mm is set, reducing idle stroke and stitch count during stitching, thereby increasing stitching efficiency by 35%. After generating the initial trajectory, turning points are smoothed using Bezier curves to mitigate impact during needle movement.

[0041] Sewing Equipment Adjustment: The intelligent control system selects appropriate sewing parameters from a parameter library based on the fabric material of the garment pocket, its thickness of 2mm, and the stitching line trajectory parameters: a 0.3mm diameter needle with a rounded tip; soft cotton thread with a tension of 2.5N; and a sewing speed of 1600 stitches per minute. A servo motor drives the relevant components of the sewing equipment to adjust the needle's mounting position and tension adjustment mechanism. Sensors monitor the adjusted parameters in real time to ensure compliance with the set values.

[0042] Suturing Execution: The suturing device is activated, and suturing is performed according to the preset suture trajectory and adjusted parameters. During the suturing process, sensors monitor the suturing status in real time at a sampling frequency of 1000Hz. Force sensors monitor thread tension and the force between the needle and the fabric, displacement sensors monitor component displacement, and image sensors capture images of the sutured area. If the image sensor detects slight irregularities in the stitches at the sutured area, the control system immediately adjusts the needle's trajectory to restore the stitches to their original alignment. If the tension sensor detects that the thread tension deviates from 2.5N, the tension adjustment device automatically adjusts the tension to restore the tension to normal.

[0043] Quality Inspection and Repair: After suturing is complete, the stitched areas are inspected for quality using ultrasonic and visual inspection. The ultrasonic inspection system's probe scans the stitched areas, capable of detecting internal defects up to a depth of 2mm with an accuracy of ±0.2mm. The visual inspection system's high-definition camera captures images of the stitched areas with a resolution of 20 megapixels. A deep learning algorithm analyzes these images and identifies surface defects such as uneven stitch length and leaky seams with 99% accuracy. Inspection revealed a stitch length slightly exceeding 2mm, with a deviation of 0.3mm. The suture thread adjustment mechanism automatically adjusted the thread feed speed and tension based on this deviation, restoring the stitch length to 2mm at that location. No leaks or internal defects were found, and no repairs were required.

[0044] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A process for sewing internal parts of an automatic cutting machine, characterized in that: The following steps are involved: Parts positioning and pre-processing steps: Use a high-precision visual recognition system to identify and locate the internal parts placed on the workbench of the automatic cutting machine, obtain the precise position and posture information of the parts, and pre-process the parts through a vacuum adsorption device and a mechanical leveling device; Suture line planning step: Based on the shape, size and design requirements of the internal components, an optimized path planning algorithm is used to generate the suture line trajectory in the computer control system; Suturing device adjustment step: automatically adjusting parameters of the suturing device according to the suture line planning results and the material and thickness of the internal components, the parameters including the type of suture needle, thread tension and suturing speed; Suture execution steps: start the sewing device of the automatic cutting machine and sew according to the preset sewing line trajectory and adjusted parameters; Quality inspection and repair steps: After suturing is completed, the sutured parts are inspected for quality using a non-destructive testing device, and defects detected in the parts are repaired using an automated repair device.

2. A process for sewing internal components of an automatic cutting machine according to claim 1, characterized in that: The high-precision visual recognition system uses multiple cameras, which are distributed around and above the workbench of the automatic cutting machine to form an all-round shooting angle. The camera frame rate is 30 frames per second, which can capture the dynamic changes of components in real time, ensuring effective identification and positioning during the component placement process.

3. The process for sewing internal components of an automatic cutting machine according to claim 1, characterized in that: During the component positioning and pretreatment steps, the adsorption pressure of the vacuum adsorption device is adjusted according to the material of the component. For softer fabric materials, the adsorption pressure is set to 0.03-0.05 MPa; for harder leather materials, the adsorption pressure is set to 0.06-0.08 MPa to ensure that the component can be firmly adsorbed without causing damage to the component.

4. A process for sewing internal components of an automatic cutting machine according to claim 1, characterized in that: The optimized path planning algorithm performs trajectory smoothing after generating the suture line trajectory, and smoothly transitions the turning points on the trajectory through Bezier curves, thereby reducing the impact and vibration of the suture needle during movement and improving the stability and accuracy of suturing.

5. The process for sewing internal components of an automatic cutting machine according to claim 1, characterized in that: The suturing equipment adjustment step adopts an intelligent control system for adjustment. The parameter library of the intelligent control system is updated regularly. By collecting suturing data and quality feedback during the actual production process, the parameters are optimized and supplemented to adapt to the ever-changing materials and production requirements.

6. A process for sewing internal components of an automatic cutting machine according to claim 1, characterized in that: In the suturing execution step, sensors are used to monitor the suturing status in real time, and the sensors include force sensors, displacement sensors and image sensors.

7. A process for sewing internal components of an automatic cutting machine according to claim 1, characterized in that: The nondestructive testing device includes an ultrasonic testing device and a visual testing device. The ultrasonic testing device detects defects within a depth of 2 mm inside the sutured part with a detection accuracy of ±0.2 mm; the visual testing device analyzes the image of the sutured part through a deep learning algorithm to accurately identify uneven stitch length and leaking seam defects.

8. The process for sewing internal components of an automatic cutting machine according to claim 1, characterized in that: The automated repair device includes an automatic seam-filling mechanism and a suture thread adjustment mechanism. The automatic seam-filling mechanism automatically adjusts the position of the suture needle to repair the seam according to the detected leaking seam position; the suture thread adjustment mechanism repairs the area with uneven stitch length or inappropriate thread tension by adjusting the thread feed amount and tension.

Images