Sewing apparatus and method of taking material

Abstract

This application discloses a sewing device and a material handling method. The sewing device includes a frame, a material transfer device, a material storage device, and a material distribution device. The material transfer device includes a pressure plate and a moving assembly. The pressure plate includes a first needle group and a second needle group. The first needle group is adapted to connect to a first end, and the second needle group is adapted to connect to a second end. Embroidery eyelet fabric is stacked vertically in the material storage device. The material distribution device is connected to the frame and includes a distribution plate. The sewing device has a single pressing state, an intermediate state, and a double pressing state. In the single pressing state, only the first needle group connects to the embroidery eyelet fabric, and the first needle group connects to the first end of the embroidery eyelet fabric located on the top layer of the material storage device. The material distribution device moves from the first end to the second end to allow the sewing device to enter the intermediate state. In the intermediate state, only one piece of embroidery eyelet fabric is laid on the distribution plate. In the double pressing state, both the first needle group and the second needle group connect to the embroidery eyelet fabric. This application ensures single-piece material handling.

Description

Technical Field

[0001] This application relates to the field of textile technology, and in particular to a sewing device and a material handling method. Background Technology

[0002] In the field of automated sewing equipment, the automatic gripping and feeding of eyelet fabric is a key step in achieving continuous production in hat-making. Eyelet fabric, as a specialized material for sewing eyelets, typically has specific shape characteristics, with differences in area at both ends, and encompasses various types of fabric with varying thicknesses and textures. Due to its thin texture and smooth surface, this type of fabric is susceptible to static electricity, negative pressure, or interlayer adhesion during automated processing, causing multiple layers to stick together and making it difficult to grip each piece precisely.

[0003] Traditional automated material handling technologies often employ methods such as vacuum adsorption or mechanical clamping. However, for thin, sheet-like objects like embroidered fabric, conventional gripping methods struggle to balance positioning accuracy and gripping stability, often resulting in the simultaneous gripping of multiple pieces of fabric at once. Summary of the Invention

[0004] The main purpose of this application is to propose a sewing device and a material feeding method that can guarantee single-piece feeding.

[0005] To achieve the above objectives, some embodiments of this application propose a sewing device for gripping embroidered fabric, the embroidered fabric having a first end and a second end, the area of ​​the first end being smaller than that of the second end, the sewing device comprising: frame, The material transfer device includes a pressure plate and a moving assembly. The moving assembly is connected to the frame and is adapted to adjust the position of the pressure plate. The pressure plate includes a first needle group and a second needle group. The first needle group is adapted to connect to a first end, and the second needle group is adapted to connect to a second end. A storage device is connected to a frame. The storage device is suitable for holding embroidered fabric, which is stacked vertically in the storage device. A material distribution device is connected to a frame. The material distribution device includes a material distribution plate with a horizontal surface. The material distribution plate is adapted to move from a first end to a second end. The sewing equipment has a single pressing state, an intermediate state, and a double pressing state. In the single pressing state, only the first needle group is connected to the embroidery eyelet fabric, and the first needle group is connected to the first end of the embroidery eyelet fabric located on the top layer of the material storage device. The material distribution device moves along the direction from the first end to the second end to allow the sewing equipment to enter the intermediate state. In the intermediate state, only one piece of embroidery eyelet fabric is laid on the material distribution plate, and both the first needle group and the second needle group are spaced apart from the embroidery eyelet fabric laid on the material distribution plate. In the double pressing state, both the first needle group and the second needle group are connected to the embroidery eyelet fabric.

[0006] In some embodiments, the first needle assembly includes a first needle tip and a first cylinder, the first needle tip is connected to a pressure plate, the first cylinder is connected to the first needle tip, and the first cylinder is used to control the length of the first needle tip extending out of the pressure plate; The second needle assembly includes a second needle head and a second cylinder. The second needle head is connected to a pressure plate, and the second cylinder is connected to the second needle head. The second cylinder is used to control the length of the second needle head extending beyond the pressure plate.

[0007] In some embodiments, the second needle assembly includes at least two second needle tips, and on a plane parallel to the surface of the pressure plate, the position of at least one second needle tip is offset from the line connecting the first needle tip and one of the second needle tips.

[0008] In some embodiments, in the secondary pressing state, the length of the second needle extending out of the pressure plate is greater than or equal to the length of the first needle extending out of the pressure plate.

[0009] In some embodiments, during a single press-down state, the length of the first needle extending beyond the pressure plate is configured to pierce only one piece of embroidered fabric.

[0010] In some embodiments, the transfer device further includes a first sensor connected to the frame, the first sensor facing the storage device, and the first sensor being adapted to detect embroidered fabric located in the storage device.

[0011] An embodiment of the second aspect of this application provides a material taking method, including the sewing equipment described above, the material taking method comprising: Stacking the embroidered eyelet fabric; The first set of needles pierced the top layer of embroidered fabric; The pressure plate moves upward, lifting the first end; The dividing plate is inserted between the lifted embroidered fabric and other fabrics; The movement of the dividing plate separates the top layer of embroidered fabric from other fabrics, and the top layer of embroidered fabric is laid on the dividing plate. Both the first and second needle sets pierced the embroidered fabric laid on the dividing board.

[0012] In some embodiments, the step of moving the dividing plate to separate the top layer of embroidered fabric from other fabrics, and laying the top layer of embroidered fabric on the dividing plate, includes: The first needle retracts to allow the embroidered eyelet fabric to detach from the press plate.

[0013] In some embodiments, after the step of moving the dividing plate to separate the top layer of embroidered fabric from other fabrics, and after the top layer of embroidered fabric is laid on the dividing plate, the material handling method includes: The pressure plate moves down to fit the embroidered fabric on the dividing plate; The first needle extends from the pressure plate to pierce the embroidered fabric; The second needle extends out of the pressure plate to pierce the embroidered fabric.

[0014] In some embodiments, the step of extending the second needle to pierce the embroidery fabric includes: The second needle extends longer than the first needle.

[0015] According to the above embodiments, the beneficial effects of this application are: The sewing equipment of this application is used to grasp embroidered eyelet fabric, which has a first end and a second end, the area of ​​the first end being smaller than that of the second end. The sewing equipment includes a frame, a material transfer device, a material storage device, and a material distribution device. The material transfer device includes a pressure plate and a moving assembly, which is connected to the frame and adapted to adjust the position of the pressure plate. The pressure plate includes a first needle group and a second needle group, the first needle group being adapted to connect to the first end and the second needle group being adapted to connect to the second end. The material storage device is connected to the frame and is adapted to hold the embroidered eyelet fabric, which is stacked vertically in the storage device. The material distribution device is connected to the frame and includes a distribution plate with a horizontal surface, adapted to move from the first end toward the second end. The sewing equipment has a single pressing state, an intermediate state, and a double pressing state. In the single pressing state, only the first needle group is connected to the embroidery eyelet fabric, and the first needle group is connected to the first end of the embroidery eyelet fabric located on the top layer of the material storage device. The material distribution device moves along the direction from the first end to the second end to allow the sewing equipment to enter the intermediate state. In the intermediate state, only one piece of embroidery eyelet fabric is laid on the material distribution plate, and both the first needle group and the second needle group are spaced apart from the embroidery eyelet fabric laid on the material distribution plate. In the double pressing state, both the first needle group and the second needle group are connected to the embroidery eyelet fabric.

[0016] This application achieves stable and precise gripping of soft, thin, or static-prone embroidery fabrics through a three-stage gripping process: a primary pressure state, an intermediate state, and a secondary pressure state. In the primary pressure state, only the first needle group connects to the smaller end of the embroidery fabric, while the second needle group remains spaced apart. This localized piercing method effectively reduces the contact area and lifting resistance during gripping, avoiding the problem of multiple pieces sticking together due to interfacial adhesion or negative pressure effects, while also reducing the risk of pulling down the lower layer of fabric due to large-area piercing. Subsequently, the separating device moves from the first end to the second end, causing the lifted top layer of fabric to completely separate from the lower layer under its own weight and the cutting action of the separating plate, and smoothly lay on the horizontal separating plate surface, forming the intermediate state. At this time, both the first and second needle groups are spaced apart from the fabric, creating conditions for secondary precise positioning. In the secondary pressure state, both the first and second needle groups simultaneously connect to the embroidery fabric, achieving comprehensive and stable gripping of the entire piece of fabric. This step-by-step grasping strategy of first lifting, then separating, and then grasping optimizes the traditional linear one-time grasping process into a cyclical process with intermediate transition positioning links. This improves the reliability and positional accuracy of grasped single pieces, and can achieve efficient and stable automated feeding without relying on a complex servo compensation system. It effectively balances production efficiency and grasping quality, and is particularly suitable for processing diverse embroidered fabrics with large differences in material properties.

[0017] To further explain the principle of this application, specifically, this application utilizes the structural characteristics of the embroidered eyelet fabric: the first end has a small area and is easily lifted, while the second end has a large area and easily adheres to the lower layer of fabric. A step-by-step gripping mechanism combining a single pressing state and a double pressing state is designed. In the single pressing state, the first needle of the first needle group only pierces and lifts the first end of the top layer of embroidered eyelet fabric. At this time, the second end remains in place due to its own weight and adhesion to the lower layer of fabric, forming an inclined state where the front end of the fabric is lifted and the rear end is lowered. The material separating device then moves along the direction from the first end to the second end. Its horizontal surface separating plate cuts into the fabric at the fork, physically separating the lifted top layer of fabric from the stacked fabric below. Simultaneously, the first needle remains in the piercing state to fix the position of the first end of the lifted fabric. Combined with the positioning function of the storage device, the position of the remaining fabric remains unchanged, thus allowing the lifted fabric to be gripped. The top layer of fabric is laid flat on the surface of the distribution plate under tension. This separation process effectively eliminates the risk of multiple layers being lifted simultaneously due to negative pressure adsorption or the adhesive force between fabrics, ensuring that only a single layer of fabric is transferred to the distribution plate. Subsequently, the transfer device enters a secondary pressing state, and the pressure plate presses down again and pierces the first end of the fabric that has been laid flat on the distribution plate again, completing the reliable gripping of a single piece of material in a more stable posture. This fundamentally solves the technical problems of soft and thin fabrics being prone to carrying lifting plates, unstable gripping, and falling off midway during the automated gripping process, and realizes precise control and stable transfer of single-piece material.

[0018] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or from practice of this application. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0020] Figure 1 This is a three-dimensional structural diagram of a sewing device viewed from a first perspective in one embodiment of this application. Figure 2 yes Figure 1 Enlarged view of point A in the middle; Figure 3 This is a three-dimensional structural diagram of a sewing device viewed from a second perspective in one embodiment of this application. Figure 4 This is a three-dimensional structural diagram of a sewing device viewed from a third-person perspective in one embodiment of this application. Figure 5 This is a three-dimensional structural diagram of the storage device viewed from a fourth perspective in one embodiment of this application; Figure 6 for Figure 5 A partial blast-damaged structural diagram of the intermediate storage unit; Figure 7 This is a three-dimensional structural diagram of the material transfer device viewed from a fifth perspective in one embodiment of this application; Figure 8 This is a three-dimensional structural diagram of the material transfer device viewed from a sixth perspective in one embodiment of this application; Figure 9 for Figure 8 Enlarged view at point B in the middle; Figure 10 This is a three-dimensional structural diagram of the material dispensing device viewed from a seventh perspective in one embodiment of this application; Figure 11 This is a three-dimensional structural diagram of the material dispensing device viewed from an eighth perspective in one embodiment of this application; Figure 12 This is a three-dimensional structural diagram of the storage device viewed from a ninth perspective in one embodiment of this application; Figure 13This is a partial structural diagram of the sewing equipment in operation in one embodiment of this application, wherein the first end of the embroidery fabric is lifted by the first needle group, the second end is still attached to other fabrics, and the separating plate is about to be inserted between the lifted embroidery fabric and other fabrics. Figure 14 This is a flowchart of a material handling method in one embodiment of this application.

[0021] Explanation of icon numbers: Sewing equipment 10; Embroidery fabric 20; First end 21; Second end 22; Material transfer device 100; pressure plate 110; first needle group 111; second needle group 112; moving component 120; first sensor 130; Storage device 200; positioning pin 210; side guard 220; material box bottom plate 230; second sensor 240; Material distribution device 300; Material distribution plate 310; Figure 11 and Figure 12 1. Right material rack base plate for embroidered eyelet; 2. Cylinder fixing bracket assembly; 3. Three-axis cylinder; 4. Material box lifting base plate assembly; 5. Support shaft for embroidered eyelet material rack; 6. Platform plate for right material rack for embroidered eyelet; 7. Guide rail; 8. Slide rail fixing block for embroidered eyelet; 9. Separation plate for right material rack for embroidered eyelet; 10. Photoelectric sensor; 11. Fixing sheet metal for embroidered eyelet cylinder; 12. Connecting sheet metal for embroidered eyelet cylinder; 13. Limiting sheet metal for embroidered eyelet guide rail; 14. MGC20X275S mini cylinder; 15. Floating joint; 16. Thorium spike pad; 17. TRN12-04NO proximity sensor; 18. Clamping cylinder; 19. Through-type trapezoidal lead screw; 20. Positioning pin.

[0022] The realization of the purpose, functional features and advantages of this application will be further explained with reference to the accompanying drawings and embodiments. Detailed Implementation

[0023] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0024] It should be noted that if the embodiments of this application involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indicators will also change accordingly.

[0025] Furthermore, if the embodiments of this application involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the use of "and / or," "and / or," or "and / or" throughout the text implies three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed in this application.

[0026] In existing technologies, automatic gripping devices for embroidered fabrics typically employ needle-punching gripping mechanisms, achieving mechanical connection by piercing the fabric with needles. However, such devices generally use a single downward pressure, with all needles simultaneously penetrating to the bottom, lacking an adaptive adjustment mechanism based on the physical properties of the fabric. When dealing with soft and thin fabrics, a single large-area needle punching can easily cause multiple layers of fabric to be pulled up due to negative pressure adsorption or interfacial adhesion.

[0027] The following is for reference. Figures 1 to 14 This application describes a sewing device 10 and a material handling method according to embodiments of the present application. (Refer to...) Figures 1 to 13 The first aspect of this application provides a sewing device 10 for gripping embroidered fabric 20, see reference. Figure 2 The embroidery fabric 20 has a first end 21 and a second end 22, the area of ​​the first end 21 being smaller than that of the second end 22. The sewing equipment 10 includes a frame, a material transfer device 100, a material storage device 200, and a material distribution device 300. The material transfer device 100 includes a pressure plate 110 and a moving assembly 120. The moving assembly 120 is connected to the frame and is adapted to adjust the position of the pressure plate 110. The pressure plate 110 includes a first needle group 111 and a second needle group 112. The first needle group 111 is adapted to connect to the first end 21, and the second needle group 112 is adapted to connect to the second end 22. The material storage device 200 is connected to the frame and is adapted to hold the embroidery fabric 20. The embroidery fabric 20 is stacked vertically in the material storage device 200. The material distribution device 300 is connected to the frame and includes a material distribution plate 310. The surface of the material distribution plate 310 is horizontal, and the material distribution plate 310 is adapted to move along the direction from the first end 21 to the second end 22. (Refer to...) Figure 13The sewing device 10 has a single pressing state, an intermediate state, and a double pressing state. In the single pressing state, only the first needle group 111 is connected to the embroidery fabric 20, and the first needle group 111 is connected to the first end 21 of the embroidery fabric 20 located on the top layer of the storage device 200. The second needle group 112 does not pierce the embroidery fabric 20. The material distribution device 300 moves along the direction from the first end 21 to the second end 22 to allow the sewing device 10 to enter the intermediate state. In the intermediate state, only one piece of embroidery fabric 20 is laid on the material distribution plate 310, and the first needle group 111 and the second needle group 112 are spaced apart from the embroidery fabric 20 laid on the material distribution plate 310. In the double pressing state, the first needle group 111 and the second needle group 112 are both connected to the embroidery fabric 20.

[0028] This application achieves stable and precise gripping of soft, thin, or static-prone embroidery fabric 20 by setting a three-stage gripping process: a first pressing state, an intermediate state, and a second pressing state. In the first pressing state, only the first needle group 111 connects to the smaller first end 21 of the embroidery fabric 20, while the second needle group 112 remains spaced apart. This localized piercing method effectively reduces the contact area and lifting resistance during gripping, avoiding the problem of multiple pieces sticking together due to the adhesive force between fabrics or the negative pressure effect, while also reducing the risk of pulling down the lower layer of fabric due to large-area piercing. Subsequently, the material separating device 300 moves along the direction from the first end 21 to the second end 22, causing the lifted top layer of fabric to completely separate from the lower layer of fabric under its own weight and the cutting action of the material separating plate 310, and lay smoothly on the surface of the horizontal material separating plate 310, forming the intermediate state. At this time, both the first needle group 111 and the second needle group 112 are spaced apart from the fabric, creating conditions for secondary precise positioning. Under the secondary pressure state, the first needle group 111 and the second needle group 112 simultaneously connect to the embroidery fabric 20, achieving comprehensive and stable gripping of the entire piece of fabric. This step-by-step gripping strategy of lifting, separating, and then gripping optimizes the traditional linear one-time gripping process into a cyclical process with intermediate transition positioning links, improving the reliability and positional accuracy of gripped individual pieces. It can achieve efficient and stable automated feeding without relying on a complex servo compensation system, effectively balancing production efficiency and gripping quality. It is particularly suitable for processing diverse embroidery fabrics 20 with significant differences in material properties.

[0029] To further explain the principle of this application, specifically, this application utilizes the structural characteristics of the first end 21 of the embroidered eyelet fabric 20, which has a small area and is easy to lift, while the second end 22 has a large area and easily adheres to the lower layer of fabric. A step-by-step gripping mechanism combining a single pressing state and a double pressing state is designed. In the single pressing state, the first needle of the first needle group 111 only pierces and lifts the first end 21 of the top layer of embroidered eyelet fabric 20. At this time, the second end 22 remains in place due to its own weight and adhesion to the lower layer of fabric, forming an inclined state where the front end of the fabric is lifted and the rear end is lowered. The material separating device 300 then moves along the direction from the first end 21 towards the second end 22. Its horizontal surface separating plate 310 cuts in from the fabric fork, physically cutting and separating the lifted top layer of fabric from the stacked fabric below. Simultaneously, the first needle remains in the piercing state to fix the position of the first end 21 of the lifted fabric. Combined with the positioning function of the storage device 200, the position of the remaining fabric remains unchanged. The lifted top layer of fabric is laid flat on the surface of the distribution plate 310 under tension. This separation process effectively eliminates the risk of multiple layers being lifted simultaneously due to negative pressure adsorption or the adhesive force between fabrics, ensuring that only a single layer of fabric is transferred to the distribution plate 310. Subsequently, the transfer device 100 enters a secondary pressing state, and the pressure plate 110 presses down again and pierces the first end 21 of the fabric that has been laid flat on the distribution plate 310 again, so as to complete the reliable gripping of a single piece of material in a more stable posture. This fundamentally solves the technical problems of soft and thin fabrics being prone to carrying lifting plates, unstable gripping, and falling off midway during the automated gripping process, and realizes precise control and stable transfer of single-piece material.

[0030] It should be noted that the eyelet fabric 20 in this application refers to a specific shaped fabric used in the hat-making process for sewing the eyelet area. In some embodiments, the eyelet fabric 20 has an asymmetrical structural feature with a first end 21 and a second end 22, and the area of ​​the first end 21 is smaller than that of the second end 22. The fabric has an eyelet hole in the center for the positioning needle 210 to pass through to achieve multi-layer stacking and positioning. At the same time, its material covers a variety of fabric types with different thicknesses and softness. It needs to be accurately grasped by a single piece through automated equipment for subsequent sewing processing.

[0031] Furthermore, it can be understood that the core technical idea of ​​this application is to achieve stable single-piece material picking of thin, soft, and easily sticky materials by combining step-by-step grasping with mechanical intervention separation, which is applicable to a variety of fluid media or fluid-like media materials with similar physical properties. For example, flexible thin-film media, which are lightweight and easily adsorbed by electrostatic or negative pressure, are prone to problems such as simultaneous lifting or adhesion during automated stacking and unloading processes. The step-by-step gripping and cutting separation mechanism of this application can effectively overcome these problems. Another example is multi-layered sheet-like soft composite materials, which have weak interlayer bonding but are prone to interfacial adsorption during rapid gripping. A progressive mode of partial lifting with initial pressure, separation by the material distribution plate 310, and stable gripping with secondary pressure can achieve reliable separation and transfer of single-layer materials. Furthermore, soft gaskets with viscoelastic surfaces are prone to adhesion after being stacked under pressure, and their irregular shape makes stable material handling difficult with traditional vacuum adsorption or overall needle punching. This application's time-division gripping strategy targeting the two ends with area differences and the horizontal cutting action of the mechanical separation plate can ensure accurate acquisition and stable transfer of single-piece materials, improving the reliability and adaptability of automated processing of such media.

[0032] Reference Figures 1 to 4 In some embodiments, the frame refers to the basic component that forms the overall structural support frame of the sewing equipment 10. It is used to fix and support all functional components such as the material transfer device 100, the material storage device 200, and the material distribution device 300, providing a stable installation reference and relative positional relationship for each device. This ensures that the translational movement of the moving component 120, the vertical pressing action of the pressure plate 110, the horizontal movement of the material distribution plate 310, and the vertical stacking storage of the material storage device 200 can all operate collaboratively within a precise spatial coordinate system. It is the mechanical foundation for realizing the overall structural integration of the equipment and the linkage and coordination of various functional modules. In some embodiments, the frame is a gantry frame structure with a crossbeam component spanning the working area. This provides a long-stroke linear motion guide for the moving component 120 of the material transfer device 100, while symmetrically arranging the material storage device 200 and the material distribution device 300 on both sides of the crossbeam to achieve an efficient dual-station alternating material handling mode. In some embodiments, the frame is a cantilever support structure, with one end fixed to the base and the other end extending to form an open working space, facilitating the quick loading, unloading, and maintenance of the storage device 200. The dispensing device 300 can be integrated into the cantilever end and the transfer device 100 to form a compact material handling unit, suitable for space-constrained automated production line layouts. In some embodiments, the frame is a modular combined frame, assembled from profile components with standardized interfaces. The stroke range of the transfer device 100, the material holding height of the storage device 200, and the intervention angle of the dispensing device 300 can be flexibly adjusted according to the specifications and dimensions of the embroidered fabric 20 and process requirements, enabling rapid reconfiguration and functional expansion of the equipment structure to meet personalized configuration needs in different application scenarios.

[0033] Reference Figures 1 to 4 In some embodiments, the material transfer device 100 refers to a functional module connected to the frame for grasping and spatially transferring the embroidery fabric 20. It consists of a moving component 120 and a pressure plate 110. The moving component 120 provides the pressure plate 110 with horizontal translational movement capability. The pressure plate 110 carries the first needle group 111 and performs vertical pressing and lifting actions. Through the step-by-step cooperation of a first pressing state and a second pressing state, the complete material transfer process is completed, from grasping the fabric from the top layer of the storage device 200, separating it through the material separating device 300, and transferring it to the target station. In some embodiments, the material transfer device 100 is an articulated robotic arm transfer system. It realizes the spatial pose adjustment of the end effector through the linkage of multi-degree-of-freedom rotary joints. It can complete the transfer of fabric from the storage station to the sewing station under complex trajectories. Moreover, the end flexible clamping module can simulate the step-by-step actions of the pressure plate 110 and the needle group, first partially clamping and lifting, and then stabilizing the whole grasp. In some embodiments, the material transfer device 100 is a high-speed transfer mechanism driven by a linear motor. It utilizes the principle of direct electromagnetic drive to achieve non-contact, high-precision linear motion, enabling rapid response to the switching requirements between primary and secondary pressing states. Combined with pneumatic or electric actuators, it achieves precise timing control of needle gripping and release, improving the material handling cycle time and positioning accuracy. In some embodiments, the material transfer device 100 is a parallel-configuration gripping platform. Through the coordinated drive of multiple sets of telescopic branches, it achieves six degrees of freedom motion of the moving platform. The pressure plate 110 and the needle assembly can be integrated below the moving platform, rapidly switching spatial postures between primary and secondary pressing states. Simultaneously, the high rigidity of the parallel structure ensures stability during needle gripping, making it suitable for high-speed, high-frequency automated material handling operations.

[0034] Reference Figures 1 to 4In some embodiments, the storage device 200 refers to a feeding module connected to the frame for vertically stacking and storing multiple pieces of embroidered fabric 20. It provides a continuous and orderly source of top-layer material for the transfer device 100 by stacking embroidered fabric 20 with a first end 21 and a second end 22, where the area of ​​the first end 21 is smaller than that of the second end 22, in a specific posture. It also works with the distribution device 300 to achieve precise vertical positioning and layered management of the fabric, serving as a fundamental material storage unit to ensure the stable operation of automated continuous grasping operations. In some embodiments, the storage device 200 is a rotary feeding mechanism. It achieves cyclical supply of fabric through multiple storage stations arranged circumferentially on a horizontal rotary table. When the material at one station is completely grasped, the rotary table rotates to switch to the next station to continue feeding. Simultaneously, vacant stations can be manually replenished, enabling parallel processing of continuous operation and offline replenishment. In some embodiments, the storage device 200 is a chain-type circulating lifting mechanism, which uses trays spaced apart on a closed chain to support the stack of fabric. Through the stepping motion of the chain, each layer of fabric is sequentially lifted to a fixed picking height. This, combined with the step-by-step gripping action of the transfer device 100, forms a rhythmic feeding mechanism. The chain's circulation path can adapt to the needs of fabric stacks of different heights. In some embodiments, the storage device 200 is a flexible vibratory feeder directional feeding system. Through controllable vibration excitation, the randomly stacked thin fabric is adjusted in posture and arranged in an orderly manner in a specific cavity. The first end 21 and the second end 22 are automatically oriented using the fabric's own shape characteristics. Then, it is conveyed to the top of the distribution device 300 in a single-layer flat manner, providing the transfer device 100 with a top layer of material that is uniform in posture and easy to grip in steps.

[0035] Reference Figures 1 to 4In some embodiments, the material separating device 300 refers to a functional module connected to the frame, used to separate the fabric between the first and second pressing states of the material transfer device 100. The material separating device 300 includes a horizontally surfaced material separating plate 310, which can move horizontally from the first end 21 to the second end 22. It cuts and separates the lifted top layer of embroidered fabric 20 from the stacked fabric below and lays it flat on its upper surface, thereby ensuring that the material transfer device 100 can stably grasp single pieces of material in the second pressing state. It is the core execution mechanism for realizing the core process logic of separating before grasping. In some embodiments, the material separating device 300 is an airflow-assisted separation mechanism. It injects a directional and controllable airflow into the gap between the lifted material and the lower layer material to break the negative pressure adsorption between layers and assist the lateral unfolding of the material. At the same time, the horizontally moving support plate intervenes synchronously with the airflow to complete the receiving and flattening of the material. It is suitable for film materials with high surface flatness requirements. In some embodiments, the material distribution device 300 is an electrostatic adsorption separation platform, which utilizes the selective adsorption of specific polar materials by an electrostatic field. When the material transfer device 100 presses down and lifts the first end 21 of the material, the second end 22 of the material is adsorbed by the electrostatic field force and kept in a drooping posture. Subsequently, the horizontally moving insulating separation plate cuts off the electrostatic field effect and transfers the material onto it, achieving contactless separation and support. In some embodiments, the material distribution device 300 is a negative pressure adsorption conveyor belt mechanism, whose surface is evenly distributed with adsorption holes and circulates horizontally. When the material transfer device 100 lifts the top layer of material, the conveyor belt cuts in from the material branch and receives the lower surface of the material by negative pressure adsorption. As the conveyor belt rotates, the material is spread out and transported to the secondary gripping station, completing the continuous operation of separation and transfer.

[0036] Reference Figure 13 Regarding the first pressing state, it should be noted that the first pressing state refers to the initial working stage of the material transfer device 100 executing the step-by-step grasping process. In this state, the pressure plate 110 moves downward in the vertical direction, causing the first needle of the first needle group 111 to extend and pierce the smaller first end 21 of the embroidery fabric 20 stacked on the top layer of the storage device 200. Subsequently, the pressure plate 110 is raised to partially lift the first end 21 of the fabric, while the larger second end 22 remains in place due to its own weight and adhesion to the lower layer of fabric, forming an inclined posture with the front end of the fabric raised and the rear end hanging down, creating the necessary conditions for the intervention and separation of the material separating plate 310.

[0037] Reference Figure 13Regarding the intermediate state, it should be noted that the intermediate state refers to the state after the first needle group 111 pierces the first end 21 of the top layer embroidery fabric 20 and is lifted during the first pressing state. The material distribution plate 310 of the material distribution device 300 moves along the first end 21 towards the second end 22, cutting and separating the top layer embroidery fabric 20 from the lower layer fabric, so that only one piece of embroidery fabric 20 is laid on the horizontal surface of the material distribution plate 310. At this time, the first needle group 111 and the second needle group 112 are spaced apart from the embroidery fabric 20 and have not formed a connection. This state is the transition positioning stage before the second pressing.

[0038] Reference Figure 13 Regarding the secondary pressing state, it should be noted that the secondary pressing state refers to the final working stage of the step-by-step grasping process executed by the material transfer device 100. In this state, the pressure plate 110 moves downward again in the vertical direction, causing the first needle of the first needle group 111 to extend and pierce the first end 21 of the embroidery fabric 20 that has been laid on the surface of the material distribution plate 310, thereby lifting the single piece of fabric in a stable, flat position, completing the reliable grasping after separation from the storage device 200 and the material distribution device 300, and ensuring that the material transfer device 100 can transfer the single piece of material to the subsequent sewing station.

[0039] To ensure more stable gripping of the embroidery fabric 20 during the secondary pressing state, the sewing device 10 can be equipped with a gripping structure other than the first needle group 111, which constrains the embroidery fabric 20 during the secondary pressing state. For example, the auxiliary gripping structure can be a second needle group 112, etc. In some embodiments, the auxiliary gripping structure is a negative pressure adsorption auxiliary module, which is disposed on the lower surface of the pressure plate 110 and distributed around the first needle group 111. During the secondary pressing state, it uses vacuum negative pressure to tightly adhere the non-needle-punched area of ​​the embroidery fabric 20 to the bottom surface of the pressure plate 110, forming a surface contact constraint to suppress the swaying and slippage of the fabric during the transfer process. In some embodiments, the auxiliary gripping structure is a flexible clamping auxiliary mechanism, which is arranged on the edge of the pressure plate 110 in the form of elastic clips or pneumatic fingers. During the secondary pressing state, it performs clamping from the side of the fabric while simultaneously performing needle-punching gripping, and restricts the horizontal displacement degree of freedom of the fabric through controllable clamping force to avoid inertial deviation during high-speed material transfer. In some embodiments, the auxiliary gripping structure is a magnetic adsorption auxiliary component, which uses the electromagnet or permanent magnet embedded in the pressure plate 110 to generate a magnetic attraction effect with the magnetic fibers or metal wires composite in the embroidered fabric 20. In the secondary pressing state, the non-contact magnetic constraint enhances the bonding strength between the fabric and the pressure plate 110, which is particularly suitable for gripping fine fabrics where it is not advisable to increase the needle-punching density to avoid damaging the surface.

[0040] Reference Figures 7 to 9In some embodiments, the first needle assembly 111 includes a first needle head and a first cylinder. The first needle head is connected to the pressure plate 110, and the first cylinder is connected to the first needle head. The first cylinder is used to control the length of the first needle head extending beyond the pressure plate 110. The second needle assembly 112 includes a second needle head and a second cylinder. The second needle head is connected to the pressure plate 110, and the second cylinder is connected to the second needle head. The second cylinder is used to control the length of the second needle head extending beyond the pressure plate 110. By configuring independent cylinder drive structures for each needle assembly, precise and controllable adjustment of the needle head extension length is achieved, thereby improving the adaptability and gripping reliability of the sewing equipment 10 to embroidery fabrics 20 of different thicknesses and materials. Specifically, the first cylinder can flexibly control the extension length of the first needle head relative to the pressure plate 110 according to process requirements, and the second cylinder can independently adjust the extension length of the second needle head. This split drive design allows each needle assembly to have differentiated parameter settings according to the fabric characteristics. During actual gripping, the piercing depth can be effectively controlled by precisely adjusting the needle extension length, avoiding problems such as weak gripping due to shallow penetration or multi-layer linkage due to excessive penetration. Simultaneously, the needle can actively retract and extend between the first and second pressing states, providing the necessary mechanical conditions for fabric separation and repositioning in intermediate states. Furthermore, the independent cylinder drive structure offers rapid response and high control precision, accurately coordinating with the overall timing control of the equipment to ensure smooth and stable transitions between states. This, in turn, guarantees a high success rate for single-piece gripping while effectively reducing equipment debugging difficulty and maintenance costs, thus improving the compatibility and operational efficiency of the automated production line.

[0041] Reference Figures 7 to 9In some embodiments, the second needle group 112 includes at least two second needles. On a plane parallel to the surface of the pressure plate 110, at least one second needle is positioned offset from the line connecting the first needle and one of the second needles. This arrangement is designed to fit different shapes of the embroidery fabric 20, thereby improving gripping stability. For example, the second needle group 112 includes two second needles, with the positions of the first needle and the two second needles forming the apex and two base angles of an isosceles triangle, respectively. By arranging the first needle and the two second needles in an isosceles triangle configuration, an optimized configuration of the gripping mechanics of the embroidery fabric 20 is achieved, improving the stability of the gripping process and the fabric posture control capability. Since the embroidery fabric 20 has an asymmetrical structural feature where the area of ​​the first end 21 is smaller than that of the second end 22, placing the first needle at the apex of the isosceles triangle to correspond to the smaller area of ​​the first end 21, and symmetrically distributing the two second needles at the base angles to correspond to the larger area of ​​the second end 22, forms a three-point support system that is both front-to-back and left-to-right balanced. This layout brings the resultant force of the gripping action closer to the geometric center of the fabric, effectively suppressing deflection, twisting, or wrinkling caused by uneven force during lifting and transfer, ensuring the fabric maintains a flat and stable posture in space. Simultaneously, the symmetrical isosceles triangle structure provides the system with excellent torsional stiffness, maintaining a reliable clamping state even with soft, easily deformable, and thin fabrics, preventing slippage or localized tearing. Furthermore, this layout synergizes with the step-by-step gripping process of initial pressure, intermediate, and secondary pressure states. When the first needle group 111 pierces the first end 21 and lifts the fabric, the two second needles have not yet intervened, creating no additional constraint resistance on the fabric, facilitating the smooth insertion of the separating plate 310 for separation. In the secondary pressure state, simultaneous piercing at three points forms a stable planar constraint, laying a solid mechanical foundation for subsequent precise transfer to the sewing station, thus improving the equipment's adaptability to gripping irregularly shaped fabrics and the overall reliability of the process.

[0042] Reference Figures 7 to 9In some embodiments, during the secondary pressing state, the length of the second needle extending out of the pressure plate 110 is greater than or equal to the length of the first needle extending out of the pressure plate 110. By setting a differentiated piercing depth where the second needle extension length is longer than the first needle extension length during the secondary pressing state, the precision requirements for the second needle extension length are reduced, the difficulty of assembly and debugging is reduced, and the optimized control of the gripping force distribution of the embroidered fabric 20 is achieved, improving gripping stability and transfer reliability. Since the second needle group 112 corresponds to the second end 22 with a larger fabric area, this end bears relatively large air resistance, inertial force, and its own gravitational torque during transfer. Configuring the second needle with a longer extension length ensures that its piercing depth is sufficient to form a strong mechanical connection, effectively resisting dynamic loads during transfer and preventing the fabric from slipping or falling off under acceleration. At the same time, the first needle corresponds to the first end 21 with a smaller area, and a relatively short extension length is sufficient to meet the gripping strength requirements of this area, avoiding fabric damage or fiber breakage that may be caused by excessive piercing. This differentiated depth configuration matches the distribution of gripping force to the mechanical needs of different parts of the fabric, creating a shallower front and deeper back anchoring effect with clear primary and secondary components. This ensures both the overall reliability of the gripping and the protection of delicate fabrics. Furthermore, this design, combined with an independent cylinder drive structure, enables precise timing control during state transitions. This allows the second needle to contact the fabric first or penetrate deeper during the second press, facilitating the rapid establishment of a stable clamping state, shortening the gripping cycle, and improving the equipment's production pace and operating efficiency. It is particularly suitable for the stable handling of soft, elastic, or easily deformable fabrics in high-speed automated sewing production lines.

[0043] Reference Figure 2 , Figures 7 to 9In some embodiments, during a single press, the length of the first needle extending from the pressure plate 110 is configured to pierce only one piece of embroidered fabric 20. By precisely configuring the extension length of the first needle during a single press to pierce only a single piece of embroidered fabric 20, precise selective grasping of multi-layered fabrics is achieved, effectively solving the problem of overlapping pieces sticking together that easily occurs in traditional grasping methods. Since the embroidered fabric 20 in the storage device 200 is stacked vertically, the fabrics are prone to adhesion due to factors such as electrostatic adsorption, surface tension, or fiber entanglement. If the needle penetration depth is too large, it is very easy to pierce the lower layer of fabric as well, resulting in the phenomenon of grasping multiple pieces at once, which seriously affects the subsequent sewing quality and causes material waste. By strictly limiting the extension length of the first needle during a single press, so that its penetration depth just penetrates the thickness of the top layer of fabric without touching the lower layer of fabric, the possibility of multiple layers sticking together is fundamentally cut off, ensuring that only one piece of fabric is lifted. This precise single-piece piercing control effectively connects with the subsequent material separating device 300. When the first needle connects to the first end 21 of the fabric at the minimum necessary depth and is lifted, the rear end of the fabric remains naturally aligned with the lower layer. This creates favorable mechanical conditions and spatial clearance for the material separating plate 310 to insert and move along the direction from the first end 21 to the second end 22, making the cutting and separating action smoother and more efficient. Simultaneously, this configuration avoids excessive stretching or damage to the fabric fibers due to excessive piercing, protecting the integrity of the embroidery fabric 20. It is particularly suitable for the fine processing of thin, soft, or highly elastic materials, significantly improving the success rate of single-piece grasping and the fabric quality retention, providing key technical guarantees for the high-reliability operation of the automated sewing equipment 10.

[0044] Reference Figures 7 to 9 In some embodiments, the transfer device 100 further includes a first sensor 130, which is connected to the frame and faces the storage device 200. The first sensor 130 is adapted to detect the embroidered fabric 20 located in the storage device 200.

[0045] By configuring a first sensor 130 facing the storage device 200 on the material transfer device 100, real-time monitoring and intelligent feedback of the presence status of the embroidery fabric 20 are achieved, improving the automation level of equipment operation and the stability of continuous production. This sensor can accurately detect the presence or absence of embroidery fabric 20 in the storage device 200, providing crucial material status information to the control system. This allows the equipment to automatically decide whether to perform a grabbing action or trigger a material shortage alarm based on the actual material condition, effectively avoiding empty grabbing, malfunctions, or production interruptions caused by human oversight. In automated sewing production lines, timely replenishment of the storage device 200 is a crucial link in ensuring continuous production. The first sensor 130 enables the equipment to have autonomous sensing capabilities, allowing it to interact with the material supply system or upper-level management system to achieve intelligent functions such as material shortage warnings, automatic material replacement, or production cycle adjustment, reducing the frequency of manual intervention and labor intensity. Meanwhile, the sensor's detection function works in conjunction with the step-by-step grasping process of the first pressing state, intermediate state, and second pressing state. It confirms the presence of material before the start of each grasping cycle, ensuring the rationality of state transitions and the effectiveness of action execution, preventing mechanical wastage and energy waste caused by empty material bins. Furthermore, the sensor's orientation towards the storage device 200 allows it to respond directly and quickly to material changes, exhibiting high detection sensitivity and short response delay. This helps improve the overall operating efficiency and reliability of the equipment, making it particularly suitable for the dynamic monitoring needs of material status in flexible production scenarios with multiple varieties and small batches.

[0046] Reference Figure 14 The second aspect of this application provides a material taking method, including the sewing equipment 10 described above, the material taking method comprising: S101: Stack 20 pieces of embroidered eyelet fabric; S103: The first stitch group 111 pierces the top layer of embroidery eye fabric 20; S105: The pressure plate 110 moves upward, lifting the first end 21; S107: The dividing plate 310 is inserted between the lifted embroidered fabric 20 and other fabrics; S109: The material separating plate 310 moves to separate the top layer of embroidered fabric 20 from other fabrics, and the top layer of embroidered fabric 20 is laid on the material separating plate 310. S111: Both the first needle group 111 and the second needle group 112 pierce the embroidery eye fabric 20 laid on the dividing plate 310.

[0047] The material handling method provided in this application achieves refined control over the entire process of grasping the embroidered fabric 20 from its stacked state to stable handling through the organic coordination of four key steps, thereby improving the reliability and positioning accuracy of the grasped single piece. First, the embroidered fabric 20 is stacked vertically in the storage device 200 to form an orderly layered material reserve, providing a stable material supply foundation for subsequent automated grasping. This stacking method makes full use of gravity to keep the fabric naturally flat, facilitating the identification and contact of the top layer of fabric. Second, the first needle group 111 pierces the top layer of embroidered fabric 20. This step adopts a partial piercing strategy, connecting only the first end 21 with a smaller fabric area, effectively reducing the contact area and lifting resistance during initial grasping, avoiding multi-layer linkage or negative pressure adsorption between fabrics caused by large-area piercing, and ensuring that only a single piece of fabric is affected by controlling the piercing depth. Subsequently, the separating plate 310 moves to separate the top layer of embroidery fabric 20 from other fabrics and lays it on its horizontal surface. This step utilizes the mechanical cutting action of the separating plate 310 to cut the interlayer adhesions, and the fabric's own weight achieves complete separation of the upper and lower fabrics. The horizontal laying posture provides a stable support benchmark and positioning reference for subsequent precise piercing. Finally, the first needle group 111 and the second needle group 112 simultaneously pierce the embroidery fabric 20 laid on the separating plate 310, achieving comprehensive clamping of the entire fabric and forming a stable and reliable three-point or multi-point connection, ensuring that the fabric maintains a flat posture and does not slip during the transfer process. This method, through a step-by-step process of stacking, preliminary piercing, separation, and stable piercing, optimizes the traditional linear gripping into a cyclical process with intermediate transition positioning, effectively solving the problems of heavy pieces and misalignment when gripping soft, thin, or easily static-prone fabrics, and improving the adaptability and production stability of the automated sewing equipment 10.

[0048] In some embodiments, the step of moving the dividing plate 310 to separate the top layer of embroidered fabric 20 from other fabrics, and laying the top layer of embroidered fabric 20 on the dividing plate 310 includes: The first needle retracts to allow the embroidered eyelet fabric 20 to detach from the pressure plate 110.

[0049] By incorporating a first needle retraction step during the fabric separation process of the separating plate 310, the active separation between the embroidered fabric 20 and the pressure plate 110 is achieved. This creates the necessary mechanical conditions for the fabric to be smoothly laid on the surface of the separating plate 310, improving the reliability of the separation action and the controllability of the fabric posture. Specifically, after the first needle group 111 completes the piercing and lifting of the first end 21 of the top layer fabric, the first needle performs a retraction action, causing the needle to exit the fabric fibers and be completely retracted into or below the end face of the pressure plate 110. At this time, the fabric falls naturally under its own weight and disengages from the pressure plate 110. This active release mechanism avoids interference or obstruction caused by the continuous penetration of the needle through the fabric to the subsequent movement of the separating plate 310, and eliminates the risk of fabric hanging, shifting, or tearing caused by needle-cloth adhesion. Subsequently, the separating plate 310 moves from the first end 21 towards the second end 22, using its thin blade edge to insert into the gap between the top and bottom layers of fabric to perform a cutting and separating action. Since the first needle has retracted, the rear end of the fabric is in a free-hanging state, allowing the separating plate 310 to smoothly support the bottom surface of the fabric and push it away from its original stacking position. At the same time, the fabric gradually flattens and lays on the horizontal surface of the separating plate 310 during the movement. This step ensures a smooth and orderly transition from lifting to laying, providing a stable horizontal support benchmark for the fabric in the intermediate state. This lays a good positioning foundation for the accurate piercing of the first needle group 111 and the second needle group 112 during the subsequent secondary pressing, effectively improving the continuity of the entire material handling process and the stability of the gripping quality.

[0050] In some embodiments, after the step of separating the top layer of embroidered fabric 20 from other fabrics by moving the separating plate 310, and after the top layer of embroidered fabric 20 is laid on the separating plate 310, the material handling method includes: The pressure plate 110 moves down to fit the embroidered fabric 20 on the material distribution plate 310; The first needle extends from the pressure plate 110 to pierce the embroidered eye fabric 20; The second needle extends from the pressure plate 110 to pierce the embroidered fabric 20.

[0051] By sequentially executing three steps—the downward movement of the pressure plate 110, the extension and piercing of the first needle, and the extension and piercing of the second needle—after separating and laying the fabric on the separating plate 310, the fabric 20 is accurately captured and stably clamped twice, improving the reliability of the gripping and the control of the transfer posture. First, the pressure plate 110 moves down to fit the fabric 20 on the separating plate 310. This action makes the end face of the pressure plate 110 form a surface contact or near-surface contact with the fabric surface, effectively flattening the fabric and eliminating wrinkles, curling, or displacement that may occur during the separation and laying process. This provides a flat reference plane and accurate positioning reference for the needle piercing. At the same time, the physical constraint of the pressure plate 110 restricts the lateral movement freedom of the fabric. Subsequently, the first needle extends from the pressure plate 110 to pierce the embroidered fabric 20. At this time, the first needle changes from a retracted state to an extended state, penetrating the first end 21 area of ​​the fabric to a controllable depth, re-establishing the mechanical connection with the fabric. This step transforms the first needle assembly 111 from an initial temporary lifting role to a final stable anchoring role, ensuring that the front end of the fabric has a reliable force support point during subsequent transfer. The second needle extends from the pressure plate 110 to pierce the embroidered fabric 20, forming symmetrical or balanced piercing points in the second end 22 area of ​​the fabric with a larger area, forming a multi-point clamping system together with the first needle. The extension action of the second needle can be performed after the first needle pierces, or in a specific timing sequence to achieve step-by-step loading and reduce instantaneous stress on the fabric. The piercing of the second needle can also be performed synchronously with the first needle. The sequential execution of these three steps completes the transition from the material distribution plate 310 supporting the fabric to the needle assembly fully grasping it. This allows the fabric to obtain stable spatial constraints based on horizontal positioning, effectively resisting inertial forces and airflow disturbances during the transfer process. It ensures that the fabric is delivered to the sewing station in a flat posture, improving the process stability and finished product quality consistency of the automated material handling method.

[0052] In some embodiments, the step of extending the second needle to pierce the embroidery fabric includes: The second needle extends longer than the first needle.

[0053] By setting the extension length of the second needle to be longer than that of the first needle during the piercing step, optimized control of the gripping force distribution of the embroidered fabric 20 and hierarchical design of the anchoring effect are achieved, improving the stability of secondary capture and resistance to dynamic loads. Specifically, with the pressure plate 110 attached to the fabric and the first needle having completed its piercing, the second needle penetrates the larger area of ​​the second end 22 of the fabric with a relatively longer extension length, forming a deeper and more secure mechanical anchoring point. This differentiated depth configuration allows the second end 22 area to obtain stronger clamping force to cope with the larger inertial force and gravitational torque generated during the transfer process due to its larger area and greater mass distribution, effectively preventing the fabric from slipping or falling off during acceleration or deceleration. At the same time, the relatively short extension length of the first needle is sufficient to meet the gripping strength requirements of the first end 21 area of ​​the fabric, avoiding fiber damage or hole deformation caused by excessive piercing, thus balancing gripping reliability and fabric quality protection. This shallow-to-deep piercing depth layout is adapted to the asymmetrical structural feature of the embroidered fabric 20, where the area of ​​the first end 21 is smaller than that of the second end 22. This ensures that the distribution of gripping force matches the mechanical requirements of different parts of the fabric, forming a well-balanced and stable clamping system with clear primary and secondary components. Furthermore, this step, along with the preceding steps such as the downward movement of the pressure plate 110 and the extension of the first needle for piercing, creates a synergistic effect. The contact constraint of the pressure plate 110 provides a stable reference plane for differentiated piercing, and the step-by-step extension action reduces the concentrated stress on the fabric at the same time, lowering the risk of deformation and fabric tearing during the piercing process. Overall, this improves the adaptability of the material handling method to diverse fabric materials and its operational reliability in high-speed automated production scenarios.

[0054] Below, refer to Figures 1 to 14This paper systematically describes the sewing equipment 10 and material handling method of this application in one specific embodiment. The sewing equipment 10 of this application is used to automatically grasp embroidery eyelet fabric 20 with a first end 21 and a second end 22, wherein the area of ​​the first end 21 is smaller than that of the second end 22. This application effectively solves the problems of unstable grasping, high overlap rate and insufficient positioning accuracy caused by differences in fabric material in traditional automatic embroidery eyelet feeding machines through an innovative step-by-step grasping process. The sewing equipment 10 mainly includes four core components: a frame, a material transfer device 100, a material storage device 200 and a material distribution device 300. The material transfer device 100 includes a pressure plate 110 and a moving component 120. The moving component 120 is connected to the frame and is adapted to adjust the position of the pressure plate 110. The pressure plate 110 is equipped with a first needle group 111 and a second needle group 112, wherein the first needle group 111 is adapted to connect to the first end 21 of the fabric and the second needle group 112 is adapted to connect to the second end 22 of the fabric. The storage device 200 is connected to the frame and is used to carry the embroidered fabric 20 stacked in the vertical direction; the separating device 300 is also connected to the frame and includes a horizontal separating plate 310, which is adapted to move along the direction from the first end 21 to the second end 22 to separate the fabric.

[0055] The core of this invention lies in optimizing the traditional one-time full-disc piercing process into a three-stage grasping process with a first pressing state, an intermediate state, and a second pressing state. In the first pressing state, the first needle group 111 connects to the first end 21 of the embroidery fabric 20 located on the top layer of the storage device 200, while the second needle group 112 remains spaced from the embroidery fabric 20. At this time, only the first needle group 111 performs partial piercing and lifting on the front end of the fabric, effectively reducing the grasping contact area and initial resistance, and avoiding the problem of multiple pieces being linked together due to large-area piercing or deep piercing. Subsequently, the material distribution device 300 moves along the direction from the first end 21 to the second end 22, causing the sewing device 10 to enter the intermediate state. In this state, only one piece of embroidery fabric 20 is laid on the surface of the material distribution plate 310, and both the first needle group 111 and the second needle group 112 are spaced from the fabric. The horizontal surface of the material distribution plate 310 provides stable transition support and positioning reference for the fabric. Finally, in the secondary pressing state, both the first needle group 111 and the second needle group 112 are connected to the embroidery eye fabric 20, achieving comprehensive and stable gripping of the entire piece of fabric. This chain design of lifting, separating, and gripping effectively cuts off the adhesion between the upper and lower fabrics through the intermediate transition positioning link, reducing the risk of overlapping pieces, while providing a precise positioning reference for secondary capture and reducing reliance on complex servo compensation systems.

[0056] In terms of the specific needle assembly structure, the first needle assembly 111 includes a first needle and a first cylinder, and the second needle assembly 112 includes a second needle and a second cylinder. Each cylinder is used to control the length of the corresponding needle extending out of the pressure plate 110, achieving precise and controllable adjustment of the piercing depth. The second needle assembly 112 includes two second needles. The positions of the first needle and the two second needles respectively form the apex and two base angles of an isosceles triangle, creating a three-point support layout that echoes each other front and back and balances left and right, effectively suppressing the deflection and twisting of the fabric during the transfer process. In the secondary pressing state, the length of the second needle extending out of the pressure plate 110 is configured to be longer than the extension length of the first needle to accommodate the larger area and mechanical requirements of the second end 22 of the fabric, forming a differentiated anchoring effect that is shallower in the front and deeper in the back. In the primary pressing state, the extension length of the first needle is strictly configured to pierce only one piece of embroidered fabric 20, fundamentally eliminating the phenomenon of multiple layers being connected. In addition, the material transfer device 100 is also equipped with a first sensor 130, which faces the storage device 200 and is used to detect the presence or absence of embroidered fabric 20, providing status feedback for the automated operation and intelligent decision-making of the equipment. The storage device 200 is equipped with a material box bottom plate 230 and a second sensor 240. The material box bottom plate 230 can lift the stacked fabric in a timely manner to compensate for the height, and the second sensor 240 is used to detect whether the top layer of embroidered fabric 20 is at a preset height.

[0057] The material handling method of this application includes the following steps: stacking the embroidered eyelet fabric 20, the first needle group 111 piercing the top layer of fabric, the separation plate 310 moving to separate the fabric and laying it on the separation plate 310, and both the first needle group 111 and the second needle group 112 piercing the fabric. During the separation process of the separation plate 310, the first needle retracts to allow the embroidered eyelet fabric 20 to detach from the pressure plate 110, ensuring that the fabric can fall smoothly and be laid on the surface of the separation plate 310; then the pressure plate 110 moves down to adhere to the fabric, and the first and second needles extend sequentially or simultaneously to pierce the fabric, completing the secondary capture. By controlling the timing and parameter configuration of each step, the method of this application effectively solves the problem of differences in the thickness and hardness of cap material during the automated grasping process, improves production efficiency, ensures production quality, and has good equipment compatibility and operational stability.

[0058] Furthermore, referring to Figure 11 and Figure 12 , Figure 11 and Figure 12The detailed structural design of the material distribution device and the material storage device is given, specifically including: 1. Embroidery eye right material rack base plate, 2. Cylinder fixing frame assembly, 3. Three-axis cylinder, 4. Material box lifting base plate assembly, 5. Embroidery eye material rack support shaft, 6. Embroidery eye right material rack platform plate, 7. Guide rail, 8. Embroidery eye slide rail fixing block, 9. Embroidery eye right material rack separation plate, 10. Photoelectric sensor, 11. Embroidery eye cylinder fixing sheet metal, 12. Embroidery eye cylinder connecting sheet metal, 13. Embroidery eye guide rail limiting sheet metal, 14. MGC20X275S mini cylinder, 15. Floating joint, 16. Thorium spike pad, 17. TRN12-04NO proximity, 18. Clamping cylinder, 19. Through trapezoidal lead screw, and 20. Positioning pin.The right-side material rack base plate 1 of the embroidered eyelet fabric provides the installation reference for the entire material distribution and storage device, forming the structural support foundation of the components. The cylinder fixing bracket assembly 2 is installed on the right-side material rack base plate 1 to fix the MGC20X275S mini cylinder 14, ensuring the stable arrangement of the drive components. The three-axis cylinder 3 is also installed on the right-side material rack base plate 1 of the embroidered eyelet fabric, providing the embroidered eyelet material box assembly with rising and falling movements, facilitating the quick installation and disassembly of the material box. The material box lifting base plate assembly 4 is connected to the through trapezoidal screw 19, which realizes vertical lifting under the drive of the screw to compensate for changes in the stacking height of the fabric. The embroidered eyelet fabric rack support shaft 5 is set vertically to provide lateral edge positioning for multi-layer stacked embroidered eyelet fabric. To prevent fabric from tipping over or shifting; the right-side fabric shelf platform plate 6 serves as an intermediate mounting layer, facilitating the arrangement of the guide rail 7 and cylinder components, while also providing movement space and installation reference for the right-side fabric shelf separation plate 9; the guide rail 7 is fixed to the right-side fabric shelf platform plate 6 via the embroidery eye slide rail fixing block 8, providing precise guidance for the reciprocating linear motion of the right-side fabric shelf separation plate 9; the right-side fabric shelf separation plate 9, as the core actuator, has a thin-blade structure at its front end to reduce insertion resistance. Driven by the MGC20X275S mini cylinder 14, it moves horizontally along the direction of the guide rail 7 to achieve the cutting and separation of adjacent fabrics. The middle contact area between the separation plate and the fabric emphasizes the balance between material hardness and support force, ensuring both... Effective separation while stably supporting the fabric; photoelectric sensor 10 is installed at an appropriate position on the right embroidery frame platform plate 6 to detect the position status of the material box lifting base plate assembly 4 and provide feedback signals to the control system; the embroidery cylinder fixing sheet metal 11 and the embroidery cylinder connecting sheet metal 12 cooperate to achieve a reliable connection between the MGC20X275S mini cylinder 14 and the right embroidery frame separation plate 9; the floating joint 15 compensates for installation errors and motion deviations, ensuring smooth transmission; the embroidery guide rail limiting sheet metal 13 is arranged at both ends of the guide rail 7 to limit the stroke limit of the right embroidery frame separation plate 9 and prevent slippage; the thorium needle pad 16 is set at the bottom of the material box as a protective pad for the needle-punching assembly, avoiding... The design prevents damage to the rigid substrate from direct impact of the needle; the TRN12-04NO proximity switch 17 detects the lower limit of the through-type trapezoidal lead screw 19, and works with the photoelectric sensor 10 to achieve bidirectional limit protection for the lifting stroke; the clamping cylinder 18 automatically presses down and clamps after the embroidery box assembly is placed in place, preventing the box from swinging or shifting during material retrieval; the through-type trapezoidal lead screw 19 is driven by a stepper motor, and through threaded transmission, it achieves precise height adjustment of the lifting base plate assembly 4 of the embroidery box, ensuring that the top layer of fabric is always at a constant material retrieval plane; the positioning pin 20 is set on the lifting base plate assembly 4 of the embroidery box, and cooperates with the positioning hole at the bottom of the embroidery box assembly to achieve rapid and accurate positioning of the box and consistency in repeated installation. The above components work together to enable the material distribution device to precisely intervene between the first and second pressing states of the material transfer device, completing the separation and support functions of the fabric. At the same time, the storage device provides structural protection for continuous and stable single-piece material retrieval through automatic lifting compensation and reliable clamping positioning.

[0059] Furthermore, the actions of the right-side material holder component for the embroidered eyelet are implemented as follows: i. In the initial state, the MGC20X275S mini cylinder 14 is in the extended state. Through the embroidered eye cylinder connecting sheet metal 12 and floating joint 15, it drives the embroidered eye right material rack separation plate 9 to the rightmost position, so that the opening of the internal cavity enclosed by the embroidered eye right material rack base plate 1 and the embroidered eye right material rack platform plate 6 is fully exposed, which facilitates the insertion of the embroidered eye material box assembly. At the same time, the clamping cylinder 18 is in the extended state to avoid space for the material box placement.

[0060] ii. The three-axis cylinder 3 pushes upward, driving the material box lifting base plate assembly 4 and positioning pin 20 to rise synchronously, so as to facilitate the placement operation of the embroidery eye material box assembly.

[0061] iii. After the embroidery box assembly is placed in, the clamping cylinder 18 retracts to clamp the embroidery box assembly, thus reliably fixing the box.

[0062] iv. The three-axis cylinder 3 retracts downward, driving the material box lifting base plate assembly 4 and positioning pin 20 to descend synchronously, completing the placement and positioning of the material box.

[0063] v. When the equipment starts operating, the embroidery eyelet feeding component moves from the initial position to the picking position. The gripping function component starts to press down, and after pressing down to the position, the front set of needles starts to pierce and grab the top cap piece, while the rear two sets of needles remain stationary. The gripping function component lifts up, at which point the front end of the cap piece is pulled up, while the rear end remains in its original position due to its own weight, the positioning effect of the mold ejector pin in the embroidery eyelet material box component, and the adhesive force of the two cap pieces.

[0064] vi. The MGC20X275S mini cylinder 14 begins to retract, and through the fixed sheet metal 11 of the eyelet cylinder, the connected sheet metal 12 of the eyelet cylinder, and the floating joint 15, the right material rack separating plate 9 of the eyelet cylinder moves to the left along the guide rail 7 to perform a cutting action. The eyelet guide rail limiting sheet metal 13 provides limit protection for the end point of the stroke. The thickness of the area in the middle of the right material rack separating plate 9 that contacts the cap piece is designed to be as thin as possible to reduce insertion resistance, while a material with a certain degree of hardness is selected to ensure support. Under the cutting of the right material rack separating plate 9, the upper and lower cap pieces are separated, and the first cap piece is picked up and falls on the right material rack separating plate 9. At this time, the mold ejector pin is still in the eyelet of the cap piece, which plays the role of positioning the cap piece with high accuracy.

[0065] vii. The gripping component presses down again to pick up the material. During the pressing process, the first set of needles retracts its needles and releases the front end of the gripping cap. After pressing down to the end, the first set of needles and the second set of needles simultaneously grip the cap. After achieving stable gripping, the gripping component lifts up again.

[0066] viii. The translation function of the embroidery eyelet feeding component begins to feed material to the sewing station of the sewing machine, completing the gripping and transfer of a single cap piece.

[0067] Furthermore, the actions of the embroidery eyelet box component are implemented as follows: After the embroidery eyelet material box assembly is inserted into the embroidery eyelet right material rack assembly, the clamping cylinder 18 retracts to clamp the embroidery eyelet material box assembly, and the three-axis cylinder 3 retracts downward, driving the material box lifting base plate assembly 4 and the positioning pin 20 to descend synchronously, completing the placement and positioning of the material box. When the equipment is running, the material box lifting base plate assembly 4 moves upward under the push of the through trapezoidal screw 19. The TRN12-04NO proximity switch 17 and the photoelectric sensor 10 work together to detect its lifting position, so that the cap piece placed on the thorium needle pad 16 is always at a fixed horizontal plane, which facilitates the gripping function component to grip the cap piece; the embroidery eyelet rack support shaft 5 provides lateral edge positioning for the cap piece, ensuring that the stacked fabric remains neat and orderly during the lifting process.

[0068] In summary, this application enables stable and high-precision transmission of single pieces of lightweight fabric, effectively solving problems in existing technologies such as fabric adhesion, negative pressure adsorption, or large-area needle punching leading to heavy piece handling, mid-process drops, and downtime rework. The machine features a compact hardware layout, with functional modules organically linked through the frame. The clear and explicit control logic facilitates the development and execution of automation programs, improving the production efficiency, single-piece material handling success rate, and finished product quality consistency of automated hat-making production lines. It provides a reliable technical solution for the automated processing of lightweight and soft materials.

[0069] The above are merely preferred embodiments of this application and do not limit the patent scope of this application. Any equivalent structural transformations made based on the content of the specification and drawings of this application under the concept of this application, or direct / indirect applications in other related technical fields, are included within the patent protection scope of this application.

Claims

1. A sewing device for gripping embroidered eyelet fabric, the embroidered eyelet fabric having a first end and a second end, the area of ​​the first end being smaller than that of the second end, characterized in that, include: frame, A material transfer device includes a pressure plate and a moving assembly. The moving assembly is connected to the frame and is adapted to adjust the position of the pressure plate. The pressure plate includes a first needle group and a second needle group. The first needle group is adapted to connect to a first end, and the second needle group is adapted to connect to a second end. A storage device is connected to the frame, the storage device being adapted to carry the embroidery fabric, the embroidery fabric being stacked vertically in the storage device; A material distribution device is connected to the frame. The material distribution device includes a material distribution plate with a horizontal surface. The material distribution plate is adapted to move along the direction from the first end toward the second end. The sewing equipment has a first pressing state, an intermediate state, and a second pressing state. In the first pressing state, only the first needle group is connected to the embroidery fabric, and the first needle group is connected to the first end of the embroidery fabric located on the top layer of the material storage device. The material distribution device moves along the direction from the first end to the second end to allow the sewing equipment to enter the intermediate state. In the intermediate state, only one piece of embroidery fabric is laid on the material distribution plate, and both the first needle group and the second needle group are spaced apart from the embroidery fabric laid on the material distribution plate. In the second pressing state, both the first needle group and the second needle group are connected to the embroidery fabric.

2. The sewing equipment according to claim 1, characterized in that, The first needle assembly includes a first needle tip and a first cylinder. The first needle tip is connected to the pressure plate, and the first cylinder is connected to the first needle tip. The first cylinder is used to control the length of the first needle tip extending out of the pressure plate. The second needle assembly includes a second needle tip and a second cylinder. The second needle tip is connected to the pressure plate, and the second cylinder is connected to the second needle tip. The second cylinder is used to control the length of the second needle tip extending out of the pressure plate.

3. The sewing equipment according to claim 2, characterized in that, The second needle assembly includes at least two second needles, and on a plane parallel to the surface of the pressure plate, the position of at least one second needle is offset from the line connecting the first needle and one of the second needles.

4. The sewing equipment according to claim 2, characterized in that, In the secondary pressing state, the length of the second needle extending out of the pressure plate is greater than or equal to the length of the first needle extending out of the pressure plate.

5. The sewing equipment according to claim 2, characterized in that, In the first pressing state, the length of the first needle extending beyond the pressure plate is configured to pierce only one piece of the embroidered fabric.

6. The sewing equipment according to claim 1, characterized in that, The material transfer device further includes a first sensor connected to the frame and facing the storage device. The first sensor is adapted to detect the embroidered fabric located in the storage device.

7. A material handling method, characterized in that, The material handling method for the sewing apparatus according to any one of claims 1 to 6 includes: Stacking the embroidered eyelet fabric; The first set of needles pierces the top layer of the embroidered eyelet fabric; The pressure plate moves upward, lifting the first end; The dividing plate is inserted between the lifted embroidered fabric and other fabrics; The separation plate moves to separate the top layer of embroidered fabric from other fabrics, and the top layer of embroidered fabric is laid on the separation plate; Both the first needle group and the second needle group pierce the embroidery fabric laid on the dividing plate.

8. The material handling method according to claim 7, characterized in that, The step of moving the dividing plate to separate the top layer of embroidered fabric from other fabrics, and laying the top layer of embroidered fabric on the dividing plate, includes: The first needle retracts to remove the embroidered fabric from the pressure plate.

9. The material handling method according to claim 7, characterized in that, After the step of the separating plate moving to separate the top layer of embroidered fabric from other fabrics, and the top layer of embroidered fabric being laid on the separating plate, the material handling method includes: The pressure plate moves down to fit the embroidered fabric on the dividing plate; The first needle extends out of the pressure plate to pierce the embroidered fabric; The second needle extends out of the pressure plate to pierce the embroidered fabric.

10. The material handling method according to claim 9, characterized in that, The step of extending the second needle to pierce the embroidery fabric includes: The extension length of the second needle is longer than that of the first needle.

Images