Robot sewing assembly
By designing a rotatable lower arm and transmission system, the sewing difficulties caused by the fixed lower arm column in robotic sewing technology are solved, enabling efficient sewing of complex 3D parts and enhancing the adaptability and flexibility of the sewing head.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-03-26
- Publication Date
- 2026-03-27
AI Technical Summary
In existing robotic sewing technology, due to the fixed lower arm column, it is difficult to effectively sew parts with complex geometries, often resulting in problems such as the sewing head colliding with or failing to make contact with the parts.
It adopts a rotatable lower arm design, which is driven by a motor to rotate around a horizontal axis. Combined with a transmission system and a programmable control system, it can maintain the position of the needle plate and butterfly looper and adapt to complex component geometries.
It enables the sewing of complex 3D planar parts, enhances the adaptability and flexibility of the sewing head, avoids collisions between the sewing head and the parts, and improves sewing efficiency.
Smart Images
Figure CN224047679U_ABST
Abstract
Description
[0001] Cross-references to related applications
[0002] This application claims priority to U.S. Provisional Application No. 63 / 571,783, filed on March 29, 2024, the disclosure of which is incorporated herein by reference in its entirety. Technical Field
[0003] Exemplary embodiments of this invention relate to the technology of robotic sewing components for sewing processes. Background Technology
[0004] Current robotic sewing technology typically includes a sewing head with a fixed lower arm column (i.e., a lower arm column in a fixed position). The presence and fixed position of the lower arm column often make sewing parts with complex geometries difficult. During sewing operations on parts with complex geometries, the lower arm column may collide with the part itself or otherwise prevent the sewing head from contacting certain parts of the part. In these or other cases, the sewing head needs to be adjusted or readjusted to allow it to complete the sewing operation.
[0005] Pivot-arm technology is already used in the hand sewing industry, particularly in the manufacture of footwear and bags or luggage. This technology does not exist in robotic sewing technology. Utility Model Content
[0006] According to one aspect of the present invention, a robotic sewing assembly is provided, comprising a sewing head body, an upper arm, a motor, and a lower arm. The upper arm is attachable to the sewing head body and includes a sewing needle oriented along a first axis. The lower arm is rotatably attached to the sewing head body to be rotatable about a second axis defined laterally by the motor relative to the first axis. The lower arm includes a needle plate, a butterfly needle, a first drive system, and a second drive system. The first drive system extends through the lower arm and is configured to hold the needle plate in position during rotation of the lower arm. The second drive system extends through the lower arm and is configured to drive the butterfly needle during rotation of the lower arm.
[0007] According to additional and / or alternative embodiments, the upper arm, sewing needle, and lower arm define an empty internal sewing area.
[0008] According to additional and / or alternative embodiments, the lower arm can rotate 160 degrees about the second axis.
[0009] According to additional and / or alternative embodiments, the lower arm and the first drive system and the second drive system are correspondingly U-shaped.
[0010] According to additional and / or alternative embodiments, at least one of the first and second transmission systems includes a concentric shaft.
[0011] According to additional and / or alternative embodiments, a counterbalance can be provided to reduce the lower arm torque requirement.
[0012] According to additional and / or alternative embodiments, a bearing can be supportably disposed on the sewing head body for supporting the lower arm on the sewing head body.
[0013] According to additional and / or alternative embodiments, the wing portion can extend outwardly from the sewing head body and the roller bearing can be attached to the lower arm so as to support the lower arm on the wing portion during rotation of the lower arm.
[0014] According to additional and / or alternative embodiments, a programmable control system is configured to perform automated control of the sewing head body, the upper arm, the lower arm, and the lower arm rotation. The programmable control system includes a sensor system for measuring a distance between the lower arm and the article being sewn, and the programmable control system is configured to adjust the programmed operation of the sewing head body, the upper arm, the lower arm, and the lower arm rotation in accordance with readings of the sensor system.
[0015] According to one aspect of the present disclosure, a robotic sewing assembly is provided that includes a sewing head body, an upper arm, a motor, a lower arm rotation drive system, and a lower arm. The upper arm is attachable to the sewing head body and includes a sewing needle oriented along a first axis. The lower arm is rotatably attached to the sewing head body so as to be rotatable about a second axis that is defined transverse to the first axis by the motor through the lower arm rotation drive system. The lower arm includes a needle plate, a curved needle, and first and second drive systems. The first drive system is extendable through the lower arm and is configured to maintain a position of the needle plate during rotation of the lower arm. The second drive system is extendable through the lower arm and is configured to drive the curved needle during rotation of the lower arm.
[0016] According to additional and / or alternative embodiments, the upper arm, the sewing needle, and the lower arm define an empty interior sewing region.
[0017] According to additional and / or alternative embodiments, the lower arm is rotatable about the second axis by 160 degrees.
[0018] According to additional and / or alternative embodiments, the lower arm and the first and second drive systems are respectively U-shaped.
[0019] According to additional and / or alternative embodiments, at least one of the first and second drive systems includes a concentric shaft.
[0020] According to additional and / or alternative embodiments, a counterbalance is provided to reduce the lower arm torque requirement.
[0021] According to additional and / or alternative embodiments, a bearing is supportably disposed on the sewing head body for supporting the lower arm on the sewing head body.
[0022] According to additional and / or alternative embodiments, the wing can extend outwardly from the sewing head body, and a roller bearing can be attached to the lower arm for supporting the lower arm on the wing during rotation of the lower arm.
[0023] According to additional and / or alternative embodiments, a programmable control system is configured to automatically control the sewing head body, the upper arm, the lower arm, and rotation of the lower arm. The programmable control system includes a sensor system for measuring a distance between the lower arm and the article being sewn. The programmable control system is configured to adjust programmed operation of the sewing head body, the upper arm, the lower arm, and the rotation of the lower arm in accordance with readings of the sensor system.
[0024] According to additional and / or alternative embodiments, the method further includes sensing a distance between the lower arm and the article, determining whether the distance is less than a predetermined distance, and if the distance is less than the predetermined distance, adjusting driving of the robotic sewing head in accordance with a program to increase the distance.
[0025] Additional features and advantages are realized through the techniques of the present application. Other embodiments and aspects of the application are described in detail herein, and are considered a part of the claimed technology. For a better understanding of the application with the advantages and features thereof, refer to the description and to the drawings. BRIEF DESCRIPTION OF DRAWINGS
[0026] For a fuller understanding of the application, reference is made to the following description taken in connection with the accompanying drawings in which:
[0027] Figure 1A 、 Figure 1B and Figure 1C is a perspective view of a robotic sewing assembly according to an embodiment including a rotatable lower arm;
[0028] Figure 2 is an enlarged and partially cutaway perspective view of a portion of the robotic sewing assembly of FIG. 1 according to an embodiment including the rotatable lower arm;
[0029] Figure 3A 、 Figure 3B and Figure 3C are side views of a sewing needle and needle plate assembly of the robotic sewing assembly of FIGS. 1 and Figure 2 according to an embodiment;
[0030] Figure 4 is a lateral schematic view of concentric shafts of a drive system of the robotic sewing assembly of FIGS. 1 and Figure 2 according to an embodiment;
[0031] Figure 5 is a perspective view of a robotic sewing assembly according to an embodiment including FIGS. 1 andFigure 2 Perspective view of a robotic sewing assembly with a rotatable lower arm and a counterweight as shown in FIG. 1;
[0032] Figure 6 is a schematic diagram of a robotic sewing assembly, programmable control system, and sensor system according to an embodiment including FIG. 1 and Figure 2 Perspective view of a robotic sewing assembly with a rotatable lower arm and a bearing and support element as shown in FIG. 1;
[0033] Figure 7 is a schematic diagram of a robotic sewing assembly, programmable control system, and sensor system according to an embodiment including FIG. 1 and Figure 2 Perspective view of a robotic sewing assembly with a rotatable lower arm and a wing and roller bearing as shown in FIG. 1;
[0034] Figure 8 is a schematic diagram of a robotic sewing assembly, programmable control system, and sensor system according to an embodiment. DETAILED DESCRIPTION
[0035] One or more embodiments of the disclosed device are described in detail below with reference to the attached drawing figures, which are incorporated herein by reference, and the following description is made in terms of exemplary embodiments thereof.
[0036] The present utility provides the ability to sew complex 3D planar parts using a robotic sewing device, which is different from robotic sewing technology that includes a sewing head with a fixed position lower arm column. The ability of a robotic sewing head with a fixed position lower arm column can be limited in sewing parts of complex geometry, while the present utility provides a robotic sewing assembly with a lower arm that is rotatable about a horizontal axis. The rotatability of the lower arm enables rotating the lower arm about a horizontal axis while maintaining the position of the needle plate relative to the upper portion of the sewing head while actively sewing the part. Thus, while sewing the part, the lower arm can be manipulated and repositioned to optimize the sewing head to adapt to the geometry of the part. The complex 3D planar part can be an instrument panel (IP) of a vehicle.
[0037] Reference is made to Figure 1A , Figure 1B , Figure 1C and Figure 2 , a robotic sewing assembly 101 is provided, the robotic sewing assembly 101 including a sewing head body 110, an upper arm 120 attached to the sewing head body 110, the upper arm 120 including a sewing needle 121 oriented along a first axis Al and a foot 122 extending through the sewing needle 121, a motor 130, a lower arm rotation transmission system 140, and a lower arm 150. The lower arm 150 is rotatably attached to the sewing head body 110 to be rotatable about a second axis A2. The second axis A2 is defined transversely or perpendicularly relative to the first axis Al. Rotation of the lower arm 150 can be driven by the motor 130 through the lower arm rotation transmission system 140.
[0038] The lower arm rotation transmission system 140 includes a spur gear 141 and pinion gear 142 set paired with the motor 130 and a right angle gear box 143. The motor 130 drives the right angle gear box 143, which in turn drives the spur gear 141 through the pinion gear 142. The spur gear 141 is fixed to the lower arm 150 such that, with the pinion gear 142 driving the spur gear 141, the lower arm 150 rotates about the second axis A2. The lower arm 150 is mounted on a horizontal center shaft 144 that protrudes from a column portion 145 of the sewing head body 110. The lower arm 150 can be mounted on a sleeve bearing such that the lower arm 150 is supported by the horizontal center shaft 144 but does not move with rotation of the horizontal center shaft 144.
[0039] According to embodiments, the horizontal center shaft 144 can have a diameter of up to 16 millimeters or more to improve the integrity and rigidity of the mechanism.
[0040] The lower arm 150 includes a needle plate 160, a curved needle 170, a first transmission system 180, and a second transmission system 190. The first transmission system 180 can extend through the interior of the lower arm 150 and is configured to maintain the position of the needle plate 160 relative to the sewing needle 121 during rotation of the lower arm 150. The second transmission system 190 can extend through the interior of the lower arm 150 and is configured to drive the curved needle 170 during rotation of the lower arm 150.
[0041] According to embodiments, the lower arm 150, the first transmission system 180, and the second transmission system 190 can each be U-shaped. In this way, the upper arm 120, the sewing needle 121, the presser foot 122, and the lower arm 150 collectively define a substantially empty interior sewing area 201. This substantially empty interior sewing area 201 provides ample space to accommodate portions of an article being sewn (e.g., an instrument panel). The rotatability of the lower arm 150 effectively increases the size and utility of the substantially empty interior sewing area 201 by allowing the lower arm 150 to move out of the way of the article during certain sewing operations.
[0042] The needle plate 160 is free-floating on a horizontal axis. The first transmission system 180 includes a bevel gear 181, a set of interconnected shafts 182, and a connecting gear 183 disposed below the needle plate 160, and the set of interconnected shafts 182 is connected to the connecting gear 183. The bevel gear 181 is fixed to the sewing head body 110. When the lower arm 150 rotates about the horizontal center shaft 144, the bevel gear 181 drives the set of interconnected shafts 182, which in turn drives the connecting gear 183. The connecting gear 183 can be driven at a 1:1 ratio relative to the lower arm 150 as the lower arm 150 and the set of interconnected shafts 182 rotate. Thus, as the lower arm 150 rotates, the needle plate 160 rotates relative to the lower arm 150 and maintains its rotational position relative to the sewing needle 121, the presser foot 122, and the rest of the sewing head body 110.
[0043] According to embodiments, as shown in Figure 1A , Figure 1B and Figure 1C , the lower arm 150 can rotate up to 160 degrees or more about the second axis A2. That is, the lower arm 150 can rotate up to 80 degrees or more about the second axis A2 clockwise from the center position (see Figure 1B ), and the lower arm 150 can rotate up to 80 degrees or more about the second axis A2 counterclockwise from the center position (see Figure 1C ).
[0044] The butterfly needle 170 can be a butterfly needle that moves through a continuous rotational motion. This is in stark contrast to the traditional scissor needle and the flat stitch mechanism that are often used in most robotic sewing heads. The butterfly needle 170 is chosen over the flat stitch mechanism because of its compact packaging, ease of integration into the lower arm 150, and the advantages of using a chain stitch over a flat stitch.
[0045] With continued reference to Figure 2 , and additional reference to Figure 3A , Figure 3B and Figure 3C , the second drive system 190 drives the butterfly needle 170 and is connected to a bevel gear 191 mounted on the horizontal center shaft 144. The second drive system 190 includes a set of interconnected bevel shafts 192 driven by the bevel gear 191, a pulley 193, a belt 194 for transmitting rotation from the set of interconnected bevel shafts 192 to the pulley 193, a needle bar support and pulley housing 1945, and a gear 195. The butterfly needle 170 is driven by the pulley 193, which in turn is driven by the belt 194. The butterfly needle 170 is supported by the needle bar 160, which maintains its rotational position relative to the sewing needle 121, the foot 122, and the rest of the sewing components through the gear 195. The needle bar 160 is mounted to the lower arm 150 through a structural component 196 that includes a bearing 197 that allows the needle bar 160 to rotate while being subject to multi-axis constraints. A sheet metal shroud 198 prevents material from contacting the pulley 193.
[0046] With reference to Figure 4 and in accordance with embodiments, at least one of the first drive system 180 and the second drive system 190 can include concentric shafts 401 to reduce space requirements. That is, for the first drive system 180, at least a portion of the set of interconnected shafts 182 can include or be provided as concentric shafts 401, and for the second drive system 190, at least a portion of the set of interconnected bevel shafts 192 can include or be provided as concentric shafts 401.
[0047] With reference to Figure 5And according to embodiments, the robotic sewing assembly 101 can further include a counterweight 501 (motor 130 removed for clarity). The counterweight 501 can be disposed on the lower arm 150 and can be configured to effectively reduce the torque requirements associated with rotation of the lower arm 150. The counterweight 501 can be oriented so as to not intrude into or limit, to a practical extent, the substantially empty interior sewing area 201.
[0048] Referring to Figure 6 And according to embodiments, the robotic sewing assembly 101 can further include a bearing 601 and a support element 602 that can be supportedly disposed on the sewing head body 110 for supporting the lower arm 150 on the sewing head body 110. The bearing 601 and support element 602 allow the lower arm 150 to rotate and can be disposed about the horizontal center shaft 144. In this configuration, the bearing element 601 and support element 602 effectively replace the reliance on the lower arm 150 being mounted on the horizontal center shaft 144.
[0049] Referring to Figure 7 And according to embodiments, the robotic sewing assembly 101 can further include wings 701 extending outwardly from the sewing head body 110 in opposite directions to define a support plane for rotation of the lower arm 150 and a roller bearing 702. The roller bearing 702 can be attached to the lower arm 150 and support the lower arm 150 on the wings 701 during rotation of the lower arm 150. The wings 701 have a rotational length that is at least sufficient to support the full rotational capability of the lower arm 150. Thus, when the lower arm 150 can be rotated up to 80 degrees or more in a clockwise direction from a center position about the second axis A2, one of the wings 701 extends far enough to support the entire clockwise rotation of the lower arm 150, and, when the lower arm 150 can be rotated up to 80 degrees or more in a counterclockwise direction from a center position about the second axis A2, the other of the wings 701 extends far enough to support the entire counterclockwise rotation of the lower arm 150.
[0050] Referring to Figure 8, the robotic sewing assembly 101 can include a programmable control system 801, and the programmable control system 801 can include a sensor system 802. The programmable control system 801 can include a processing unit, a memory for storing executable instructions readable and executable by the processing unit, whereby the processing unit controls the operation of the robotic sewing assembly 101 in accordance with readings of the sensor system 802, and an input / output (I / O) unit through which the processing unit communicates with the robotic sewing assembly 101 and the sensor system 802. Thus, the programmable control system 801 can be configured to automatically control the respective operation of the sewing head body 110, the upper arm 120, the sewing needle 121, the lower arm 150, the rotation of the lower arm 150, and the first and second transmission systems 180, 190, without the need for operator intervention. The sensor system 802 can be configured to measure the distance between the lower arm 150 and the article being sewn. The programmable control system 801 can be further configured to adapt the programmed operation of the respective operation of the sewing head body 110, the upper arm 120, the sewing needle 121, the lower arm 150, the rotation of the lower arm 150, and the first and second transmission systems 180, 190 in accordance with readings of the sensor system 802. For example, when the size, shape, and / or configuration of the article being sewn deviates from the nominal size, shape, and / or configuration, certain parts of the robotic sewing assembly 101 are at risk of hitting the article during the sewing process, the sensor system 802 will be able to detect the possible hit, and the programmable control system 801, upon being warned of the possible hit by the sensor system 802, will be able to adapt the programmed operation to avoid the possible hit.
[0051] While the various embodiments described above are described separately, it should be understood that these embodiments can be combined together in various combinations. It should also be understood that other configurations are possible in addition to the configurations described above. For example, the motor 130 and the lower arm rotation transmission system 140 can be replaced by motorizing the roller bearing 702 in the lower arm 150, which in turn allows for corresponding adaptations to the first and second transmission systems 180, 190. Figure 7
[0052] The technical effects and advantages of the present application are to provide a robotic sewing assembly capable of sewing complex 3D planar components. The robotic sewing assembly has a rotatable lower arm, which allows the lower arm to be rotated while maintaining the position of the needle plate relative to the upper part of the sewing assembly and actively sewing the component. Therefore, when sewing the component, the lower arm can be manipulated and repositioned to optimize the sewing assembly to adapt to the geometry of the component.
[0053] The term "about" is intended to include the degree of error associated with measurements that can be expected in devices that are commercially available when submitting the application. For example, "about" can include a range of ± 8% or 5%, or 2% of a given value.
[0054] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and / or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.
[0055] While the present disclosure has been described with reference to example embodiments or implementations, those having ordinary skill in the art will understand that various changes can be made and equivalents can be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the central scope thereof. Therefore, the present disclosure is not limited to the particular embodiments disclosed as the best mode contemplated for carrying out this present disclosure, but it includes all embodiments falling within the scope of the claims.
Claims
1. A robotic sewing assembly comprising: a sewing head body; an upper arm attached to the sewing head body and comprising a sewing needle oriented along a first axis; a motor; and a lower arm rotatably attached to the sewing head body so as to be rotatable about a second axis, the second axis being defined transversely to the first axis by the motor, the lower arm comprising: a needle plate; a shank; a first drive system extending through the lower arm and configured to maintain the position of the needle plate during rotation of the lower arm; and a second drive system extending through the lower arm and configured to drive the shank during rotation of the lower arm.
2. The robotic sewing assembly of claim 1, wherein the upper arm, the sewing needle, and the lower arm constitute an empty interior sewing region.
3. The robotic sewing assembly of claim 1, wherein the lower arm is rotatable about the second axis by 160 degrees.
4. The robotic sewing assembly of claim 1, wherein the lower arm and the first drive system and the second drive system are correspondingly U-shaped.
5. The robotic sewing assembly of claim 1, wherein at least one of the first drive system and the second drive system comprises a concentric shaft.
6. The robotic sewing assembly of claim 1, further comprising a removable counterweight to reduce lower arm torque requirements.
7. The robotic sewing assembly of claim 1, further comprising a bearing supportively placed on the sewing head body for supporting the lower arm on the sewing head body.
8. The robotic sewing assembly of claim 1, further comprising: a wing extending outwardly from the sewing head body; and a roller bearing attached to the lower arm for supporting the lower arm on the wing during rotation of the lower arm.
9. The robotic sewing assembly of claim 1, further comprising a programmable control system configured to automatically control the sewing head body, the upper arm, the lower arm, and rotation of the lower arm, wherein: the programmable control system comprises a sensor system for measuring a distance between the lower arm and a sewn article, and the programmable control system is configured to adjust programmed operation of the sewing head body, the upper arm, the lower arm, and rotation of the lower arm in accordance with readings of the sensor system.
10. A robotic sewing assembly comprising: a sewing head body; an upper arm attached to the sewing head body and comprising a sewing needle oriented along a first axis; a motor; a lower arm rotation drive; and a lower arm rotatably attached to the sewing head body so as to be rotatable about a second axis, the second axis being defined transversely to the first axis by the motor through the lower arm rotation drive, the lower arm comprising: a needle plate; a shank; a first drive system extending through the lower arm and configured to maintain the position of the needle plate during rotation of the lower arm; and a second drive system extending through the lower arm and configured to drive the shank during rotation of the lower arm. 11. The robotic sewing assembly of claim 10, wherein the upper arm, the sewing needle, and the lower arm comprise an empty interior sewing area.
12. The robotic sewing assembly of claim 10, wherein the lower arm is rotatable 160 degrees about the second axis.
13. The robotic sewing assembly of claim 10, wherein the lower arm is U-shaped in correspondence with the first drive system and the second drive system.
14. The robotic sewing assembly of claim 10, wherein at least one of the first drive system and the second drive system comprises a concentric shaft.
15. The robotic sewing assembly of claim 10, further comprising a detachable counterweight to reduce lower arm torque requirements.
16. The robotic sewing assembly of claim 10, further comprising a bearing supportively disposed on the sewing head body for supporting the lower arm on the sewing head body.
17. The robotic sewing assembly of claim 10, further comprising: a wing extending outwardly from the sewing head body; and a roller bearing attached to the lower arm for supporting the lower arm on the wing during rotation of the lower arm.
18. The robotic sewing assembly of claim 10, further comprising a programmable control system configured to automatically control the sewing head body, the upper arm, the lower arm, and rotation of the lower arm, wherein: the programmable control system comprises a sensor system for measuring a distance between the lower arm and an article being sewn, and the programmable control system is configured to adjust programmed operation of the sewing head body, the upper arm, the lower arm, and rotation of the lower arm in accordance with readings of the sensor system.