Adjustable sewing cell device

Abstract

Robot sewing arrangement comprising: a holder for holding an object to be sewn; and a robotic arm comprising a sewing head, the sewing head being configured to apply seams to the object, and the robotic arm being configured to manipulate the sewing head in multiple directions relative to the object, wherein the holder comprises a servo unit to which the article is connected and which is configured to manipulate the article in multiple directions relative to the sewing head, and The robot arm, sewing head and servo unit can be operated together.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 63 / 571,770, filed March 29, 2024, the disclosure of which is incorporated herein by reference in its entirety. BACKGROUND

[0002] Exemplary embodiments of the present disclosure relate to the art of robotic sewing assemblies for use in sewing processes.

[0003] Robotic sewing technology often includes a sewing head. The sewing head may comprise an upper arm and a lower arm and be attached to a robotic arm. The robotic arm positions the sewing head near an object to be sewn. The object, which may be, for example, but not necessarily, a vehicle dashboard (AB), is usually held in place by a fixture. The robotic arm aligns the sewing head so that a specific stitching operation can be performed relative to the object. SHORT DESCRIPTION

[0004] According to one aspect of the disclosure, a robotic sewing assembly is provided. The robotic sewing assembly includes a mount for receiving an article to be sewn and a robotic arm. The robotic arm includes a sewing head. The sewing head is configured to apply seams to the article. The robotic arm is configured to manipulate the sewing head in multiple directions relative to the article. The mount includes a servo unit to which the article is connected and which is configured to manipulate the article in multiple directions relative to the sewing head. The robotic arm, the sewing head, and the servo unit are operable together.

[0005] According to additional and / or alternative embodiments, the robot arm comprises a first arm rotatable in at least one direction, a second arm rotatably mounted to the first arm to be rotatable in at least one direction, and a coupling by which the sewing head is rotatably mounted to the second arm to be rotatable in at least two directions.

[0006] According to additional and / or alternative embodiments, the sewing head comprises a sewing needle and a stitch plate.

[0007] According to additional and / or alternative embodiments, the mount further comprises a chassis to which the servo unit is mounted and a vertically oriented shield plate supported on the chassis proximate the servo unit.

[0008] According to additional and / or alternative embodiments, the servo unit is configured to manipulate the article in the plurality of directions relative to the sewing head during sewing.

[0009] According to additional and / or alternative embodiments, the servo unit is configured to rotate and translate the object about and along multiple axes.

[0010] According to additional and / or alternative embodiments, the servo unit is configured to rotate the object about a longitudinal axis of the object, to raise and lower the object, and to guide the object laterally in a first and a second transverse direction.

[0011] According to additional and / or alternative embodiments, the robotic sewing assembly further comprises a programmable controller for controlling the robot arm, the sewing head and the servo unit to operate together without operator intervention.

[0012] According to one aspect of the disclosure, a robotic sewing assembly is provided for sewing an instrument panel (AB) having an elongated flattened portion and an elongated curved portion defining air vents. The robotic sewing assembly includes a mount for receiving the instrument panel and a robotic arm. The robotic arm includes a sewing head. The sewing head is configured to apply stitches to the instrument panel. The robotic arm is configured to manipulate the sewing head in multiple directions relative to the instrument panel. The mount includes a servo unit to which the instrument panel is connected and which is configured to manipulate the instrument panel in multiple directions relative to the sewing head.The robot arm, sewing head, and servo unit can be operated together to perform sewing on the elongated flattened portion and the elongated curved portion defining the dashboard air vents.

[0013] According to additional and / or alternative embodiments, the robot arm comprises a first arm rotatable in at least one direction, a second arm rotatably mounted to the first arm to be rotatable in at least one direction, and a coupling by which the sewing head is rotatably mounted to the second arm to be rotatable in at least two directions.

[0014] According to additional and / or alternative embodiments, the sewing head comprises a sewing needle and a stitch plate.

[0015] According to additional and / or alternative embodiments, the mount further comprises a chassis to which the servo unit is mounted and a vertically oriented shield plate supported on the chassis proximate the servo unit.

[0016] According to additional and / or alternative embodiments, the servo unit is configured to manipulate the dashboard in the plurality of directions relative to the sewing head during sewing.

[0017] According to additional and / or alternative embodiments, the servo unit is configured to rotate and translate the dashboard about and along multiple axes during sewing.

[0018] According to additional and / or alternative embodiments, the servo unit is configured to rotate the dashboard about a longitudinal axis of the article, raise and lower the dashboard, and guide the dashboard laterally in a first and a second transverse direction during sewing.

[0019] According to additional and / or alternative embodiments, the stitching is performed along a plurality of exterior and underside surfaces of the instrument panel at the elongated flattened portion, the elongated curved portion, and one or more of the vents.

[0020] According to additional and / or alternative embodiments, the robotic sewing assembly further comprises a programmable controller for controlling the robotic arm, the sewing head, and the servo unit to work together to perform the sewing on the elongated flattened portion and the elongated curved portion defining the dashboard vents without operator intervention.

[0021] According to additional and / or alternative embodiments, the article is an instrument panel (AB) of a motor vehicle and includes an elongated flattened portion, an elongated curved portion, and one or more vents, and the stitching is performed along a plurality of exterior and underside surfaces of the instrument panel at the elongated flattened portion, the elongated curved portion, and the one or more vents.

[0022] Further features and advantages are realized by the techniques of the present disclosure. Further embodiments and aspects of the disclosure are described in detail herein and are considered part of the claimed technical concept. For a better understanding of the disclosure, including the advantages and features, reference is made to the description and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] For a more complete understanding of this disclosure, reference is now made to the following brief description taken in conjunction with the accompanying drawings and detailed description, in which like reference characters represent like parts: Fig. 1 is a perspective view of an article, such as a dashboard (AB) of a motor vehicle, to be sewn according to the embodiments; Fig. 2A and Fig. 2B are perspective and side schematic views, respectively, of a robotic sewing assembly for carrying out the sewing of the article according to Fig. 1 according to embodiments; Fig. 3 is a schematic diagram of a programmable controller of the robot sewing assembly of the Fig. 2A and Fig. 2B according to embodiments; Fig. 4 is a graphical representation of a sequence of operations of the robot sewing assembly of the Fig. 2A and Fig. 2B according to embodiments; and Fig. 5 is a flowchart illustrating a method of operating a robotic sewing assembly for sewing an article, such as an instrument panel (AB) of a motor vehicle, according to embodiments. DETAILED DESCRIPTION

[0024] A detailed description of one or more embodiments of the disclosed device is presented herein by way of example and not by way of limitation with reference to the figures.

[0025] In most cases, a robotic sewing assembly mount allows access to a location on a part or object being sewn where a stitch is to be applied. However, certain part configurations prevent access to all stitch locations on the part without exceeding the limits of the robotic sewing assembly. For example, access to locations near the top of an instrument panel (AB) and the bottom of the instrument panel (AB) may be difficult in designs where this access is restricted to the top or bottom.

[0026] Therefore, as described below, a fixture is provided that is capable of adjusting the position and / or orientation of a part or object to be sewn with respect to a robotic sewing assembly. This enables faster and more efficient completion of the part or object. The part or object is attached to the fixture, and the fixture is capable of controlling the position and / or orientation of the part or object in real time to enable a sewing head of a robotic sewing assembly to access all sewing points of the part or object during the sewing process. This allows the sewing head to access those hard-to-reach areas found on certain parts or objects with particularly complex geometries.The mount is capable of moving the part or object in various ways, including, but not limited to, rotating the part or object about a specific axis and moving the part or object upward, downward, or sideways.

[0027] Referring to Fig. 1 and the Fig. 2A and Fig. 2B, a robotic sewing assembly 201 is provided for sewing an article, such as an instrument panel 101 for a motor vehicle (for clarity and brevity, the following description refers generally to the instrument panel 101, but it is understood that this terminology is and would be interchangeable with the "article"). The instrument panel includes an elongated flattened portion 110 and an elongated curved portion 120 shaped to define one or more vent openings 121. In sewing the instrument panel 101, seams are applied to a plurality of exterior and underside surfaces of the instrument panel 101, to the elongated flattened portion 110, to the elongated curved portion 120, and to edges of one or more of the vent openings 121.

[0028] The robotic sewing assembly 201 includes a mount 210 for rotatably and movably supporting the instrument panel 101 and a robotic arm 220. The robotic arm 220 includes a sewing head 230. The sewing head 230 is configured to apply the stitches to the plurality of exterior and underside surfaces of the instrument panel 101, to the elongated flattened portion 110, to the elongated curved portion 120, and to edges of one or more of the vents 121. The robotic arm 220 is configured to manipulate the sewing head 230 in multiple directions relative to the instrument panel 101. The mount 210 includes an optional base 211 to which the robot arm 220 can be anchored (although it is understood that, for example, in a robot gantry system or other similar cases, no anchoring is required or provided), and a servo unit 212 to which the dashboard 101 is connected.The servo unit 212 is configured to manipulate the instrument panel 101 in multiple directions relative to the sewing head 230. The robot arm 220, the sewing head 230, and the servo unit 212 can be operated in conjunction with each other to perform sewing on the instrument panel 101.

[0029] The servo unit 212 may include a gripping portion 2121 configured to grip the instrument panel 101 without interfering with the sewing operations, and a plurality of servo arms 2122 that are movable and rotatable relative to the instrument panel 101 and relative to each other. The gripping portion 2121 includes grippers 2123 that can grip any portion of the instrument panel 101 and can be rotatable relative to the proximal one of the plurality of servo arms 2122. The servo unit 212 is thus capable of moving and / or rotating the instrument panel 101 in and about a plurality of directions and axes. That is, the servo unit 212 can move the instrument panel 101 up and down, forward and backward, side to side, and / or about any vertical or horizontal axis.

[0030] The sewing head 230 includes a sewing needle 231 and a throat plate 232. The robot arm 220 includes the sewing head 230, an optional base 221 that can be anchored to the base part 211 of the holder 210 (as mentioned above, an optional base 221 is not present, for example, in the case of a robot gantry system or in other similar cases, and no anchoring is required or provided), a first arm 222 that is rotatable in at least one direction, a second arm 223 that is rotatably attached to the first arm 222 so as to be rotatable in at least one direction, and a coupling 224 by which the sewing head 230 is rotatably attached to the second arm 223 so as to be rotatable in at least two directions.The mount 210 includes the optional base section 211, the servo unit 212, and further includes a chassis 213 to which the optional base section 211 and the servo unit 212 are mounted at a distance from each other, and a vertically oriented screen 214 supported on the chassis 213 near the servo unit 212.

[0031] The servo unit 212 is configured to manipulate the instrument panel 101 in various directions relative to the sewing head 230 during sewing. In particular, the servo unit 212 is configured to rotate and translate the instrument panel 101 about and along multiple axes during sewing. That is, the servo unit 212 is configured to rotate the instrument panel 101 about a longitudinal axis A1 of the instrument panel 101, raise and lower the instrument panel 101 along a vertical axis A2, and move the instrument panel laterally in first and second transverse directions along transverse directions A3 and A4 during sewing. As explained further below, sewing can occur along multiple exterior and underside surfaces of the instrument panel 101 at the elongated flattened portion 110, the elongated curved portion 120, and one or more of the vents 121.

[0032] With continued reference to the Fig. 1 and the Fig. 2A and Fig. 2B and with additional reference to the Fig. 3, the robotic sewing assembly 201 may further include a programmable controller 301. The programmable controller 301 may include a processor 310, a memory unit 320, and a servo control unit 330 in signal communication with the robot arm 220, the sewing head 230, and the servo unit 212. The memory unit 320 contains executable instructions stored therein that can be read and executed by the processor 310. When the executable instructions are read and executed by the processor 310, the processor 310 effectively controls the robot arm 220, the sewing head 230, and the servo unit 212 via the servo control unit 330 so that they work together to perform the sewing operation on the instrument panel 101 without operator intervention.

[0033] With further reference to the Fig. 1-3 and with additional reference to the Fig. 4 shows a sequence 400 of operations of the robot arm 220, the sewing head 230 and the servo unit 212. As shown in Figures (1) and (2) of Fig. 4, the robot arm 220 first extends the sewing head 230 toward and over the instrument panel 101 while slightly rotating the sewing head 230. As shown in Figures (3), (4) and (5) of Fig. 4, the rotation of the sewing head 230 continues, and the servo unit 212 starts to rotate the instrument panel 101 counterclockwise so that a bottom surface of the instrument panel 101 faces the sewing head 230. As shown in Figures (4) and (5) of Fig. 4, the robot arm 220 then rotates the sewing head 230 downward and curvilinearly toward the instrument panel 101, while the servo unit 212 rotates the instrument panel 101 clockwise so that an edge of the instrument panel 101 is brought between the sewing needle 231 and the needle plate 232 at a ventilation opening 121. At this point, the robot arm 220 drives, as shown in Figures (6), (7), (8) and (9) of Fig. 4, the sewing head 230 sideways while the servo unit rotates the dashboard 101 counterclockwise so that the sewing head can sew a seam on the edge of the dashboard 101 at the ventilation opening 121. As shown in Figures (10) and (11) of Fig. 4, the robot arm 220 then rotates the sewing head around the dashboard 101 so that the sewing head can continue to apply the seam to the dashboard 101. As shown in Figure (12) of Fig. 4, this process continues until the sewing operation is completed, whereupon the robot arm 220 begins to pull the sewing head 230 away from the dashboard 101.

[0034] Referring to the Fig. 5, a method 500 for operating a robotic sewing assembly for sewing an article, such as an instrument panel (AB), is described substantially as described above with reference to the Fig. 1-4. The method 500 may be performed by a programmable controller without operator intervention. As described in Fig.5, the method 500 optionally includes anchoring a robotic arm containing a sewing head to a base portion of a fixture and / or providing the robotic arm with the sewing head and providing the fixture (block 501), connecting a servo unit of the fixture to the instrument panel (block 502), and sewing along a plurality of exterior and underside surfaces of the instrument panel (block 503). The sewing of block 503 includes simultaneously controlling the robotic arm to manipulate the sewing head relative to the instrument panel (block 5031), controlling the sewing head to apply stitches to the instrument panel (block 5032), and controlling the servo unit to rotate the instrument panel about a longitudinal axis of the instrument panel, raising and lowering the instrument panel, and guiding the instrument panel laterally in first and second transverse directions (block 5033).Thus, if the instrument panel has an elongated flattened portion, an elongated curved portion, and one or more vents, the stitching of block 503 may be performed along multiple exterior and underside surfaces of the instrument panel at least at the elongated flattened portion, the elongated curved portion, and the one or more vents.

[0035] Technical effects and advantages of the present disclosure include providing a fixture for a robotic sewing assembly capable of adjusting a position and / or orientation of a part or article being sewn relative to a sewing head of the robotic sewing assembly. This enables faster and more efficient completion of the part or article.

[0036] The term "approximately" is intended to encompass the degree of error associated with the measurement of a particular quantity based on the equipment available at the time the application is filed. For example, "approximately" may encompass a range of ± 8%, 5%, or 2% of a particular value.

[0037] 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" include the plural forms unless the context clearly indicates otherwise. It is further understood that the terms "comprising" and / or "including," when used in this specification, specify the presence of certain 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, element components, and / or groups thereof.

[0038] Although the present disclosure has been described with reference to an exemplary embodiment or exemplary embodiments, those skilled in the art will understand that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. Moreover, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment contemplated as the best mode for carrying out the present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] US 63 / 571,770

[0001]

Claims

[1] Robot sewing arrangement comprising: a holder for holding an object to be sewn; and a robotic arm comprising a sewing head, the sewing head being configured to apply seams to the object, and the robotic arm being configured to manipulate the sewing head in multiple directions relative to the object, wherein the holder comprises a servo unit to which the article is connected and which is configured to manipulate the article in multiple directions relative to the sewing head, and The robot arm, sewing head and servo unit can be operated together. [2] Robot sewing assembly according to claim 1, wherein the robot arm comprises: a first arm rotatable in at least one direction; a second arm rotatably mounted on the first arm to be rotatable in at least one direction; and a coupling by which the sewing head is rotatably mounted on the second arm so as to be rotatable in at least two directions. [3] Robot sewing assembly according to claim 1, wherein the sewing head comprises a sewing needle and a needle plate. [4] Robot sewing assembly according to claim 1, wherein the holder further comprises: a chassis to which the servo unit is attached; and a vertically aligned shield plate supported on the chassis near the servo unit. [5] The robotic sewing assembly of claim 1, wherein the servo unit is configured to manipulate the article in the plurality of directions relative to the sewing head during sewing. [6] The robotic sewing assembly of claim 1, wherein the servo unit is configured to rotate and translate the article about and along multiple axes. [7] The robotic sewing assembly of claim 1, wherein the servo unit is configured to rotate the article about a longitudinal axis of the article, raise and lower the article, and guide the article laterally in first and second transverse directions. [8] A robotic sewing assembly according to claim 1, further comprising a programmable controller for controlling the robot arm, the sewing head and the servo unit to operate together without operator intervention. [9] A robotic sewing assembly for sewing an instrument panel (AB) comprising an elongated flattened portion and an elongated curved portion defining ventilation openings, the robotic sewing assembly comprising: a bracket for holding the dashboard; and a robotic arm having a sewing head, the sewing head configured to apply stitches to the dashboard, and the robotic arm configured to manipulate the sewing head in multiple directions relative to the dashboard, wherein the mount includes a servo unit to which the dashboard is connected and which is configured to manipulate the dashboard in multiple directions relative to the sewing head, and wherein the robot arm, the sewing head and the servo unit are jointly operable to perform sewing on the elongated flattened portion and the elongated curved portion defining the air vents of the dashboard. [10] Robot sewing assembly according to claim 9, wherein the robot arm comprises: a first arm rotatable in at least one direction; a second arm rotatably mounted on the first arm to be rotatable in at least one direction; and a coupling by which the sewing head is rotatably mounted on the second arm so as to be rotatable in at least two directions. [11] Robot sewing assembly according to claim 9, wherein the sewing head comprises a sewing needle and a throat plate. [12] Robot sewing assembly according to claim 9, wherein the holder further comprises: a chassis to which the servo unit is attached; and a vertically aligned shield plate supported on the chassis near the servo unit. [13] The robotic sewing assembly of claim 9, wherein the servo unit is configured to manipulate the dashboard in the plurality of directions relative to the sewing head during sewing. [14] The robotic sewing assembly of claim 9, wherein the servo unit is configured to rotate and translate the dashboard about and along multiple axes during sewing. [15] The robotic sewing assembly of claim 9, wherein the servo unit is configured to rotate the instrument panel about a longitudinal axis of the article, raise and lower the instrument panel, and guide the instrument panel laterally in first and second transverse directions during sewing. [16] The robotic sewing assembly of claim 9, wherein the sewing is performed along a plurality of exterior and underside surfaces of the instrument panel at the elongated flattened portion, the elongated curved portion, and one or more of the vent openings. [17] The robotic sewing assembly of claim 9, further comprising a programmable controller for controlling the robot arm, the sewing head, and the servo unit to work together to perform the sewing on the elongated flattened portion and the elongated curved portion defining the dashboard vents without operator intervention.

Images