System and method for separating fabric layers

Abstract

The present invention relates to a system for handling and processing fabric layers (111). The system has a handling robot (100) comprising an effector (101) for handling fabric layers (111), the effector (101) having a handling mechanism (120) that is designed to pick up and place down at least one fabric layer (111). The handling mechanism (120) has an effector contour (106), it being possible to secure the fabric layer (111) within the effector contour (106), and the effector contour (106) being smaller than an outer contour of the fabric layer (111). The handling mechanism (120) is designed to individually separate and pick up at least one fabric layer (111) from a fabric layer stack (112), to place at least one separated fabric layer (111) flat on a work surface (102) of a work table (103), and to stretch the fabric layer (111) within the effector contour (106) without creases. The system also has a monitoring device (130) which is designed to monitor the separation of the at least one fabric layer (111) from the fabric layer stack (112).

Description

[0001] SYSTEM AND METHOD FOR SEPARATION OF FABRIC LAYERS

[0002] Technical area

[0003] The present invention relates to a system and a method for handling and processing fabric layers with a handling mechanism and a monitoring device for monitoring the separation of a fabric layer from a fabric layer stack.

[0004] Background of the invention

[0005] In the technical field of textile processing, one goal is to increase the level of automation in order to reduce personnel costs and, accordingly, production costs.

[0006] A textile processing system, which is designed for automated sewing, for example, requires a handling mechanism to separate the fabric from a stack and, after manipulation, feed it to a sewing system (or sewing machine) at a sufficient distance. For this purpose, robots with an effector are used, on which appropriate gripping mechanisms are arranged to grip the textile piece. However, fabric pieces that constitute a garment have different sizes and can have different properties both among themselves and within the same piece.

[0007] properties (thickness, air permeability, stiffness, etc.).

[0008] Gripping these thin and easily deformable textile pieces places high demands on their handling during textile processing. Various types of effectors with corresponding grippers are known in robotics for manipulating textile pieces. These grippers can be designed as contour-adaptive grippers and, for example, enable the adaptable gripping of different types of textile pieces. Furthermore, various vacuum gripping systems are known that can secure and handle the textile piece using suction cups.

[0009] Especially when separating fabric layers from a stack, it is important to ensure that, for example, only the top layer of a specific number of fabric layers is picked up. Furthermore, it is necessary that the fabric layers are picked up in a specific orientation and, for example, without wrinkles. If the predetermined number of fabric layers or the predetermined orientation and texture of the fabric layers do not match, a high level of waste will be generated even with a high degree of automation.

[0010] It is an object of the present invention to increase the quality of processing multiple layers of fabric.

[0011] This object is achieved by a system and a method for handling and processing layers of material according to the subject matter of the independent patent claims.

[0012] According to a first aspect of the present invention, a system for handling and processing fabric layers is provided. The system comprises a handling robot with an effector for handling fabric layers. The effector has a handling mechanism configured to pick up and place at least one fabric layer, wherein the handling mechanism has an effector contour. The fabric layer can be fastened within the effector contour, wherein the effector contour is smaller than an outer contour of the fabric layer. In other words, the fabric layer is larger than the effector contour and protrudes beyond the effector contour.

[0013] The handling mechanism is configured to individually separate and pick up at least one fabric layer from a fabric layer stack, wherein the handling mechanism is further configured to lay at least one separated fabric layer flat on a work surface of a work table and to stretch the fabric layer within the effector contour without creases.

[0014] The system further comprises a monitoring device configured to monitor the separation of the at least one fabric layer from the fabric layer stack. In other words, the monitoring device can monitor the process of separating the at least one fabric layer and thus ensure whether, for example, the predetermined number, i.e., one or a specific number of fabric layers, are handled.

[0015] A further aspect of the present invention describes a method for handling and processing fabric layers. The method comprises picking up and placing at least one fabric layer by means of a handling mechanism of an effector of a handling robot, wherein the handling mechanism has an effector contour and wherein the fabric layer can be fastened within the effector contour. The effector contour is smaller than an outer contour of the fabric layer, wherein the handling mechanism is configured to individually separate and pick up at least one fabric layer from a fabric layer stack and to place at least one separated fabric layer flat on a work surface of a work table.

[0016] According to the method, the fabric layer is stretched wrinkle-free within the effector contour. Furthermore, the method includes monitoring the separation of at least one fabric layer from the fabric layer stack using a monitoring device.

[0017] The handling robot has the effector, to which the corresponding handling mechanism is attached, particularly in an interchangeable manner. The handling robot is attached to the floor or workbench with a stationary robot base to introduce the corresponding forces into the corresponding system. Alternatively, the handling robot can also be configured such that the robot base is designed to be movable along the floor. A robot arm can be arranged between the effector and the robot base, which, for example, has one or more joints to thus steer the effector into a desired position.

[0018] The handling robot is a programmable, multipurpose handling device for moving material, workpieces, tools, or specialized equipment. Specifically, the handling robot is designed to handle or manipulate the layers of material and to move and position them accordingly. In other words, the handling robot enables machine-controlled position changes in more than one axis and / or along a translational position change of the layers of material.

[0019] The term fabric layer refers to the possible textiles or textile parts of a textile product, in particular a piece of clothing. The term fabric layer includes different types of knitted fabrics, in particular woven fabrics and nonwovens. The left / wrong side of a fabric layer is understood to be the inside (i.e. the underside of the fabric, inside of the fabric or the 'unsightly side' of a fabric layer. In a piece of clothing, the left side corresponds to the non-visible side of the fabric layer. The right / right side of a fabric layer is used to refer to the 'sightly side' of a fabric or fabric layer (e.g. the top side of the fabric, visible side, outside of the fabric). In a piece of clothing, the right side corresponds to the visible side of the fabric or fabric layer (e.g. the outside of a T-shirt). Furthermore, a fabric part can consist of several layers of fabric.For example, a piece of fabric (such as a garment) can be folded over several times and placed on a work table as a stack of multiple layers. Alternatively, the layers can each be separate pieces of fabric that form a stack of fabric layers.

[0020] The controllable handling mechanism is arranged on the effector. The handling mechanism transports one or more fabric layers. The fabric layers can be loosely placed on top of one another and gripped as a stack (for example, by means of negative pressure or by means of a mechanical gripper of the handling mechanism), or the fabric layers can be fastened together, for example temporarily. The handling mechanism can transport the fabric layers to a joining unit. The effector or the handling mechanism can adapt to the contour of the fabric layers, for example by adjusting the fixing points of the handling mechanism to which the fabric layer is fixed. For example, the fixing elements described below, in which the individual fixing points are formed, can be arranged for this purpose.In particular, the handling mechanism covers the outline-relevant points of a fabric layer's contour, with one edge of the fabric layers preferably remaining free as a joining area and not covered by the handling mechanism. The area of ​​the fabric layers covered by the effector or the handling mechanism for securing the fabric layers is referred to below as the effector contour.

[0021] The effector thus forms an end part of the handling robot with, for example, grippers as handling mechanisms, which grasp and manipulate a fabric layer (for example a flat, unprocessed fabric layer or an entire garment as a fabric layer) or a fabric layer stack consisting of fabric layers that are fastened with a fixing mechanism.

[0022] The joining unit is configured to process the joining areas of a fabric layer and / or to join at least two fabric layers. The joining unit can be a sewing machine, a welding machine, a tacking machine, a crocheting machine, an automatic gluing machine, or other automatic joining machines for fabric layers. The joining unit can, for example, join two fabric layers together to create a seam (fabric seam or weld seam, etc.). A seam, for example, describes the joining of two fabric layers using a thread or yarn, wherein at least one material essentially represents a fabric, a fleece, or a woven fabric.

[0023] According to the approach of the present invention, in particular, a monitoring device is provided which monitors the separation of at least one fabric layer or the plurality of fabric layers from the fabric layer stack. This ensures that precise orientation of the fabric layers and precise placement of the fabric layers is possible for later further processing, for example at the joining unit. In this case, the monitoring device can also detect, in particular, the wrinkle-free state of the fabric layers when these have been picked up by the handling mechanism within the effector contour. As explained in the exemplary embodiments, the monitoring device can detect the correct separation of the desired fabric layers by the handling mechanism, for example via a weight measurement, an optical measurement and / or via the measurement of an electromagnetic field.This allows for increased automation in textile processing, as, for example, human monitoring of the handling of fabric layers is no longer necessary; instead, the monitoring device can be automated. Furthermore, the quality of the processing of the fabric layers is also increased, as the monitoring device automatically detects errors during the separation of the fabric layers.

[0024] According to another exemplary embodiment, the monitoring device comprises an optical sensor, in particular a monitoring camera. The optical sensor is configured to detect an isolated fabric layer that has been picked up by the handling mechanism. Using an optical sensor, e.g., a camera, and suitable downstream evaluation, both the picking up of the fabric layers and their crease-free positioning after laying down can be ensured.

[0025] According to a further exemplary embodiment, the monitoring device has a weight sensor, wherein the weight sensor is arranged on the effector such that a weight of the fabric layer picked up by the handling mechanism can be measured. Additionally or alternatively, the weight sensor is installed in the work table and configured such that a change in the weight of the fabric layer stack can be measured before and after the separation of a fabric layer. In particular, by means of electronic weighing and the embedding of the result in the control system, it is determined that only one fabric layer or a desired plurality of fabric layers is detected. The fabric layer stack and / or the weight increase on the effector can be weighed before and after separation. By comparing before and after separation, it can be determined how many fabric layers have been removed from the fabric layer stack by the effector.

[0026] According to a further exemplary embodiment, the monitoring device has a tactile sensor and / or a distance sensor to determine the presence of an isolated fabric layer on the handling mechanism. The tactile, distance, or proximity sensor can be used to monitor the presence of a fabric layer held by the handling mechanism and, for example, also the thickness of the fabric layers or the total thickness of the fabric layers on the effector. A tactile sensor can be understood, for example, as a pressure sensor, which can determine how many fabric layers are held based on the penetration depth of a held fabric layer or layers with a certain pressure. A distance sensor can, for example, measure the thickness of the fabric layers. The distance sensor can, for example, be an ultrasound or an optical sensor.The pressure sensor can, for example, have an extendable piston that measures the resistance when pressing into the fabric layers. This can ensure, for example, that only one layer of fabric or a desired number of layers has been picked up. Such a device can also be used to decide when a gripping process should start and when it is complete.

[0027] According to another exemplary embodiment, the handling mechanism comprises a suction device configured to separate and pick up a fabric layer from the fabric layer stack using negative pressure. The monitoring device, in particular, comprises a vacuum sensor configured to measure an air flow of the suction device, wherein the air flow is indicative of whether the suction device is holding a fabric layer, whether multiple fabric layers are being held, or whether no fabric layer is being picked up.

[0028] The suction device has, for example, at least one suction device, wherein the suction device is designed to suck air from at least one layer of fabric to be held by means of the suction device in such a way that a layer of fabric or layers of fabric lying on top of one another can be secured to the suction device. Since the fabric layers are permeable to air to a certain extent due to their material properties, one, two or more layers of fabric in a stack of fabric layers can be secured by suction with an appropriately adjusted suction power. The suction device has, for example, a vacuum pump, which can be arranged at a distance from the effector, for example on the work table. One or more suction devices, such as suction cups, can be attached to the effector as part of the handling mechanism. Furthermore, the suction device with the suction devices can also form parts of the handling mechanism in order to align and convey the secured layers of fabric.In an exemplary embodiment, the suction device also forms part of the handling mechanism for handling the layers of fabric.

[0029] For example, the suction device can additionally form a tightening area in the work table to hold a fabric layer resting on the work table from below (based on the principle of a vacuum clamping table), while the upper fabric can be held from above with the effector. This allows for improved relative alignment between the first and second fabric layers, as the fabric layer resting on the work table remains fixed and does not slip.

[0030] The vacuum sensor can measure the air flow (in particular the volume flow) which is sucked in by the suction cups through the held fabric layers, particularly depending on the power consumption of the vacuum pump. Based on these parameters, it can be determined whether one or more fabric layers are being held. If, for example, several fabric layers are being held, the volume flow which is sucked out is reduced with a corresponding power consumption of the vacuum pump. If the inlet air flow is reduced when a vacuum suction cup picks up a piece of fabric, this can be detected as a sign of successful picking up by means of pressure monitoring on the vacuum line or flow monitoring of the sucking air flow. In addition, flow monitoring can also detect the erroneous picking up of two pieces of fabric in the case of somewhat permeable textiles. In particular, for example,It can be discriminated that the volume flow of a vacuum gripper must be between a minimum and a maximum value.

[0031] According to a further exemplary embodiment, the suction device forms a suction surface onto which one of the fabric layers or the stack of fabric layers can be placed. The suction surface has a plurality of suction openings, in particular more than 9, more than 15, more than 22 and / or more than 30 suction openings. With a handling mechanism based on negative pressure, with a small suction opening, sufficient force can only be generated with high negative pressure to hold the fabric layers. The fabric layer deforms, which could in particular make ironing necessary in a subsequent work step. On the other hand, large suction openings, even with little negative pressure, deform the textile material to such an extent that it no longer lies sufficiently flat in the xy plane. In addition, when positioning on another fabric layer, this can also be sucked in, which counteracts precise positioning.For this reason, a solution was chosen that utilizes a large number of small suction openings (distributed over a larger area or edge). Good results are achieved with more than 9, especially more than 15, preferably more than 22, and especially more than 30 suction openings. Tests with smaller diameters of these suction openings have shown that they keep the fabric layers flat in the xy plane. This, in particular, prevents warping and wrinkling during subsequent laying.

[0032] According to a further exemplary embodiment, the suction openings are designed with a diameter of less than 20 mm, in particular less than 10 mm, furthermore in particular less than 5 mm, furthermore in particular less than 3 mm. Good results were achieved with more than 9, in particular more than 15, preferably more than 22, particularly preferably more than 30 suction openings. Tests on the diameter of these suction openings have shown that diameters of less than 20 mm, in particular less than 10 mm, furthermore in particular less than 5 mm, furthermore in particular less than 3 mm are particularly advantageous because, for example, a support material inserted between layers of fabric keeps the fabric part flat in the xy plane. This prevents, in particular, warping and the formation of wrinkles when it is laid down later.

[0033] According to a further exemplary embodiment, the monitoring device comprises a sensor for measuring an electromagnetic field, wherein the electromagnetic field strength is indicative of whether the handling mechanism is holding a layer of material, whether several layers of material are being held, or whether no layer of material is being held.

[0034] In an exemplary embodiment, the handling mechanism comprises an electrostatic gripping device. For example, a contact surface, e.g., made of metal, can be formed on the effector, to which electrodes are coupled. These serve as a potential source and can thus generate an electrostatic force of attraction with the fabric layers. When picked up with an electrostatic gripping device, its energy flow and / or, using a capacitively coupled electromagnetic field, its attenuation can then be evaluated as a function of the successful picking up of an individual fabric piece.

[0035] According to a further exemplary embodiment, the handling mechanism is configured to grasp a fabric layer at fixing points to which the fabric layer is fixed by the handling mechanism. The handling mechanism is further configured such that the fixed fabric layer can be tensioned by moving the fixing points. Additionally or alternatively, the handling mechanism is further configured to fix the fabric layer at further fixing points within the effector contour and / or to re-tension it using the further fixing points. For example, appropriate vacuum suction cups, electrostatic attraction elements, or mechanical grippers can be arranged at the fixing point. Appropriate movable fixing elements, such as holding rods, which can be extended and retracted, for example, in a telescopic manner or by means of an articulated connection, can be attached to the effector, with a corresponding handling mechanism being attached to the holding rods.By moving the fixation elements, a fixation point can be moved, for example, allowing the held fabric layers to be tensioned accordingly. Especially with larger pieces of fabric, there is a risk that they will sag if they are only lifted at the relevant contour points, for example, at the edge of the effector contour. For this reason, additional fixation points and corresponding handling mechanisms can be placed within the clamped effector contour. These keep the fabric piece in the clamped plane (even during rapid position changes of the effector) and / or the holding rods or grippers can pre-tension the fabric piece in the direction 'away from the center' after it has been picked up.

[0036] According to another exemplary embodiment, the handling mechanism is further configured such that fabric layers can be picked up individually from two spaced-apart stacks of fabric layers. One of the major tasks during subsequent automatic finishing is turning fabric layers from 'right' to 'left' (or vice versa). This task can be addressed during the separation of a fabric layer from the fabric layer stack by either providing a fabric layer stack 'left side' and a fabric layer stack 'right side', or by stacking the fabric layers prior to cutting such that one layer is 'left' and one layer is 'right'. This makes it easier to create a double layer after separation, in which two fabric layers touch each other, which are 'right side', and thus the left-side surface is on the outside, which corresponds to the usual side for sewing.The dynamic gripping variations of the handling mechanism for separation according to the invention are particularly effective because the left and right sides of a fabric layer usually have slightly different quality requirements and / or technical properties.

[0037] According to a further exemplary embodiment, the effector has at least two handling mechanisms which can be selectively controlled to fix one of the fabric layers or the fabric layer stack, wherein the at least two handling mechanisms can be activated and controlled in particular depending on location and / or depending on a sensor value and / or depending on a manipulation step and / or a joining step.

[0038] According to another exemplary embodiment, the effector has at least one fixing element on which the handling mechanism or the fixing points at which the handling mechanism is located are formed. The handling mechanism is further configured to fix and transport the stack of fabric layers for handling to the joining unit, in particular within the effector contour. The handling mechanism is selected, for example, from the group consisting of grippers, suction cups, clamps, areas with increased friction and / or electrostatic attraction, holding needles, rollers, freezing grippers, and / or Bernoulli grippers.

[0039] Electroadhesive grippers for electrostatic attraction work with electrostatic fields. Holding forces are generated through polarization. They can be generated on the upper side of the fabric layer, which is in contact with a gripper dielectric of the electroadhesive gripper.

[0040] A Bernoulli gripper has a suction body, with compressed air flowing outward along the xy plane between the fabric part and the suction body via a flow channel at the edges of the suction body. An air opening is located in the center of the suction body, which is coupled to the flow channel. Due to the Bernoulli effect, air is sucked into the flow channel from the direction of the fabric part. This creates a fixation force between the fabric part and the suction body.

[0041] A freeze gripper has a highly chilled contact surface with the fabric part, whereby frozen water or ice acts as an adhesive to adhere the fabric part to the contact surface. The water can be drawn from the atmosphere (humidity) or added from an adhesive supply.

[0042] In other words, for example, several (identical or different) handling mechanisms can be arranged on a support rod of a fixing element.

[0043] According to another exemplary embodiment, the handling mechanism is controllable in such a way that different gripping intensities can be controlled for securing one or more fabric layers. If fabric layers of different thicknesses, different technical / haptic properties, or different layering (left / right) must be processed with the handling mechanism, it is advantageous if the gripping can be controlled with a further degree of freedom, namely with the different gripping intensities. In particular, a different gripping intensity and also a different handling mechanism can be selected if the fabric layer is to be gripped on the left or right side of the fabric part.For example, the right side of a fabric layer can be gently gripped using a suction device, while the left side can be picked up with holding pins, since a line on the left side of the fabric layer is acceptable. Furthermore, the gripping intensity and / or the type of handling mechanism can be selected depending on the location of the fabric layer. For example, an effector can have a handling mechanism for large fabric layers with a large surface area, and in another area of ​​the effector, a handling mechanism with several closely spaced fixation points. Thus, depending on the type of fabric layer, location-dependent gripping can be selected with one handling mechanism on the effector or with the other handling mechanism on the effector. Furthermore, the gripping intensity can be selected depending on the process step of the handling robot.For example, when lifting and separating a layer of fabric from the stack of fabric layers, a higher gripping intensity can be selected, for example, a high suction power of a suction device, but a lower gripping intensity, i.e., less suction power of the suction device when moving the layer of fabric along the work table. In the example of the suction device, appropriate control of the suction power can also prevent the suction device from becoming stuck to the work table, for example.

[0044] The fixing elements each have, for example, at least one support rod (or, as described below, a framework of coupling rods), which is movably attached to the effector at one end. Along the support rod or at a free end of the support rod, corresponding fixing devices or fixing mechanisms are provided, such as a gripper or a holding needle device having holding needles for holding the piece of fabric. The support rod can, in particular, be attached to the effector in a pivotable and / or translationally displaceable manner. Furthermore, the support rod can, for example, be telescopically extendable and retractable in order to change its length. Furthermore, the support rod itself can have at least one joint, so that the support rod itself has two sections that can be pivoted towards one another. This enables precise adjustment and setting of the gripping device of a fixing element.The adjustment of the effector contour of the effector can be made possible, for example, by integrated actuators (e.g. stepper motors with mechanical transmission to the fixation elements).

[0045] The fixing elements are arranged on the effector in such a way that at least one fixing element or all guide elements have two degrees of freedom per arm in an xy-plane and in particular a further additional degree of freedom in the z-plane (for folding away inactive grippers).

[0046] The xy plane is defined as the plane in which the fabric layer exists when it is secured by the fixing elements. Specifically, the fabric layer is spanned between the fixing elements. In this spanned state, the fabric layer has a flat shape and thus lies within the xy plane. The normal to the xy plane forms the z direction. In other words, the xy plane forms the fabric plane, and the thickness of the fabric is defined along the z direction.

[0047] According to a further exemplary embodiment, the monitoring device generates monitoring data describing the number, orientation, and / or nature of the fabric layer fixed to the handling mechanism, wherein the handling mechanism is controllable based on the monitoring data. The monitoring data can be acquired and monitored, for example, using the sensors described above. The data is processed, for example, in a control unit. The control unit can further be configured to control the handling robot and, in particular, the handling mechanism. In a further embodiment, the handling mechanisms are adapted in real time based on the sensor signals. For example, an electronic weighing device or the weight sensor of the fabric stack or the load weight on the effector can determine whether only one fabric layer has actually been separated.Alternatively, the optical sensor can monitor the manipulation progress in various work steps and, if necessary, feed back into the handling mechanism or the manipulation itself. In particular, artificial intelligence mechanisms can be used for wrinkle detection or prevention. In addition, a learning process can improve the detection and / or feedback on the robotics / gripping in this embodiment. For wrinkle detection, the unevenness can be determined using a 3D scan of the surface of the separated piece of fabric. From a certain degree of unevenness (especially if the first derivative of the Z-height of a measurement line in one of the coordinate directions produces a noticeable impulse response), wrinkle formation can be assumed. As a countermeasure, the fabric layer can be lifted again and placed back down, or the fabric layer can be sorted into a defect pile.Such an embodiment can ensure that only one piece of material is picked up during separation.

[0048] In an exemplary embodiment, the control unit is designed to control the handling robot and / or the joining unit, wherein the control unit is configured to collect and evaluate the data relating to the movement of the effector and data relating to the joining result of the joining unit, and in particular the monitoring data, in order to take measures relating to the control of the movement of the effector and the joining process of the joining unit in the event of a predetermined deviation from a predefinable limit value. The control unit can be coupled wirelessly or via cable to the individual sensors of the system in order to receive the corresponding movement data, position data, and status data of the effector, as well as the data of the joining unit, and the status data of the joining point or the joining result of the material part. Furthermore, the control unit can be provided with a storage unit having a database orbe equipped with the data processing unit or linked to a remote, web-based or cloud-stored database. The database may contain, for example, target values ​​for the data or measured parameters. Based on an actual / target value comparison, the control unit can generate corresponding control commands for the system. In other words, the system according to the invention uses the findings from the sensory evaluation to determine whether the respective manipulation was successful. In this way, a change in reliability can be detected and communicated to a higher-level system. This can be used, for example, to initiate preventive maintenance or an adjustment of the handling parameters.

[0049] According to a further exemplary embodiment, the handling mechanism comprises a holding needle device with holding needles, which is configured such that a piercing depth and / or a piercing angle of at least one holding needle can be controlled, in particular in real time and / or based on sensor feedback.

[0050] The holding needle device is configured to insert holding needles into the fabric layers for fixation. By means of the holding needle device, one or more needle-like pins or holding needles can be driven from a magazine into or through the fabric layers, either from the effector side, from the work table side, or from an auxiliary system (e.g., auxiliary plate, needle belt), in order to fasten them to one another and / or to the effector. The holding needle device has, in particular, a feed device, for example, a holding needle magazine, which is configured to feed holding needles for the holding needle device. An additional form of differentiated gripping can relate to the depth of an insertion needle or holding needle and / or the angle of a holding needle (and in particular a plurality thereof).For example, a holding pin can be inserted at a shallow angle or not as deeply into the fabric layer when separating, while with thicker fabric layers a steeper angle or a greater penetration depth can be used to securely grip the fabric layer or layers.

[0051] According to another exemplary embodiment, the holding needles have a diameter of less than 1300 micrometers, less than 900 micrometers, in particular less than 550 micrometers, and more particularly less than 250 micrometers. It has been found that, when fine microneedles are used as holding needles in combination with a suitable vacuum and a suitable air flow, no quality-impairing effects remain on the fabric surface after processing. This has been demonstrated particularly with needle diameters of less than 1300 micrometers, less than 900 micrometers, in particular less than 550 micrometers, and preferably less than 250 micrometers.

[0052] According to a further exemplary embodiment, the handling mechanism has a support element, in particular a support plate, for placing the at least one fabric layer to be conveyed, wherein the handling mechanism is in particular configured such that the fabric layer can be lifted and the support element can be conveyed under the fixed fabric layer. The support element can, for example, be fork-shaped, or the support plate can have a round support surface or a square support surface. Furthermore, the support element can have an adhesive surface so that the fabric layer does not accidentally slip off during transport or joining. The support element can, for example, be arranged in an articulated manner on the effector (e.g. via a further robot arm) in order to be inserted accordingly under or between the fabric layers.

[0053] In other words, the topmost layer(s) of fabric from a stack of fabric layers can be lifted. To do this, the handling mechanism can lift the topmost layer of fabric or at least one edge or border using the embodiments explained (e.g. using a temporary adhesive, holding or microneedles, a Bernoulli gripper, suction cups or a vacuum), so that the support element can be moved in between, i.e. can then be transported between the topmost layer(s) of fabric and the layers of fabric underneath or to the work table. In other words, the support element first moves in the x- or y-direction underneath the layer of fabric to be lifted, so that at the beginning the front edge of the support element is parallel to the straight cut edge of the layer of fabric. When the support element has been pushed underneath completely (or at least), the support element is moved vertically or horizontally together with the layer of fabric to be lifted.lifted in the z-direction and thus separated from the rest of the underlying layers of material.

[0054] According to a further exemplary embodiment, the handling mechanism is designed such that a joining region of the fabric layer, on which a joining step of a joining unit can be carried out, forms a projection of more than 0.5 cm, in particular more than 1 cm, further in particular more than 2 cm or more than 3 cm, relative to the effector contour. The resulting fabric projection defines the joining regions and enables subsequent joining. The joining region can then be placed on at least one other free joining region of a further fabric layer. Alternatively, the joining region can be manipulated such that it is folded (e.g. for a hem) and thus forms the fabric layer. It is particularly important that all handling mechanisms or fixing points are located within the effector contour.This makes it possible to eliminate edge effects, which are particularly characterized by the cutting process of the fabric layers (fibers that jam with the next lower layer, bending of cut edges in stiffer fabrics, fraying of fabric due to cutting, cutting bleeds, etc.), or to control them in handling.

[0055] A joining area of ​​a fabric layer describes an area that is to be processed with a joining unit. The joining area can, for example, be the area of ​​a fabric layer where a seam or hem can run. In particular, joining areas of two superimposed fabric layers are placed on top of each other so that they can be joined using the joining unit (e.g., by sewing or welding).

[0056] According to another exemplary embodiment, the system further comprises the work table with the work surface, wherein the work table has a hold-down device configured to selectively fix the fabric layer to the work table, in particular by means of electrostatic holding forces. The hold-down device can press against the work table / work surface with a force, which leads to a fixation of the two intermediate fabric layers. Alternatively, the effector can also allow compressed air to flow between its underside and the fabric layers. This is particularly helpful when the effector needs to reposition itself so that it can quickly overcome the adhesive forces between the effector and the first fabric layer. This allows a fabric part to be deposited safely and flatly after separation.

[0057] According to a further exemplary embodiment, the monitoring device comprises a humidity sensor. The handling mechanism, which is particularly designed as an electrostatic handling mechanism, is controllable based on the measured humidity. The system further comprises a humidification device for adjusting the humidity, wherein the humidification device is controllable based on the measured humidity. The humidity can be measured in the ambient air of the work area, and in particular in the vicinity of or in the stack of fabric. From the determined humidity values, the humidity can be increased using a suitable additional device (e.g., a humidifier) ​​to prevent disruptive electrostatic effects and / or to trigger influences on the gripping mechanism (e.g., higher holding forces when the fabric layers are moist and therefore heavier).Electrostatic gripping systems in particular are strongly influenced by material moisture and air humidity, so this type of application is particularly recommended there.

[0058] According to a further exemplary embodiment, the monitoring device is configured to detect misgripping or incorrect placement of the fabric layer on the handling mechanism, wherein the handling mechanism is configured to deposit and re-grip the fabric layer upon detection of misgripping or incorrect placement. The misgripping can be detected, in particular, by the monitoring device and its described sensors. This effectively prevents a fabric layer from being incorrectly aligned during handling due to incorrect handling (e.g., excessive compression and the resulting wrinkling) or joints between two fabric layers from being incorrectly aligned due to incorrect positioning.

[0059] According to another exemplary embodiment, the effector is designed to be replaceable. The system can comprise an effector exchange device configured to automatically couple and decouple an effector from the handling robot. The effector exchange device is particularly configured to automatically couple and decouple supply lines to the effector. The effector exchange device is further configured to transport the effector between a storage location and the handling robot. The effector can thus be deposited at a location, and another effector can be coupled to the handling robot. The required connections to resources (energy, compressed air, vacuum, data, control lines) are also connected, ensuring dust tightness. This allows contour issues to be resolved for fabric pieces of different sizes.

[0060] The effector exchange device is arranged, for example, at a storage location where a variety of different effectors with different handling mechanisms can be stored. The handling robot can place the effector at a predetermined location on the effector exchange device by moving its robot arm. The effector exchange device can be arranged locally at the storage location to accommodate the effector. For example, automatic coupling and decoupling can take place on the robot arm to place the effector at a desired location on the effector exchange device. The effector exchange device can further comprise coupling elements, such as decoupling tools, to detach corresponding fluid lines or lines between the effector and the robot arm or to connect them during coupling.Furthermore, the effector exchange device itself can have a robotic arm and move to the coupling location of the effector. Using a decoupling tool, the effector exchange device can decouple and couple the effector accordingly.

[0061] In one exemplary embodiment, the system can have an effector cleaning system, particularly at the storage location, for cleaning the effector. At the storage location, the unused effector can be (automatically) cleaned with the effector cleaning system. Surfaces with particular frictional resistance, in particular, require regular cleaning to ensure the desired friction effects. Furthermore, sensors, such as optical lenses of the optical sensor, or parts of the suction device or vacuum system, can be cleaned with the effector cleaning system.

[0062] According to a further exemplary embodiment, the effector is designed to press the fabric layer down onto a work surface of a work table. Depending on the properties of the fabric layers, additional fabric layers may be lifted during separation. For this reason, the robot can perform a hold-down action before separation and, for example, press on the stack of fabric layers. This can, for example, be a brief pressing down of the fabric stack (without the grippers activated) so that the air between the fabric layers can escape laterally. Here, the contour reduction or the reduced effector contour of the effector is advantageous, since when the stack of fabric layers is compressed, there is less obstruction to the escaping residual air between the fabric layers.

[0063] According to another exemplary embodiment, the effector is configured to perform a smoothing action on the fabric layer, particularly upon detection of a fold by the monitoring device. To perform the smoothing action, the effector is configured in particular such that the effector places the fabric layer on a work table and changes the fixing points of the handling mechanism with the fabric layer, so that the fabric layer can be smoothed.

[0064] Additionally or alternatively, to carry out the smoothing action, the

[0065] Effector may have a roller unit which is particularly configured such that the effector places the fabric layer on a work table and smooths the fabric layer by means of the roller unit.

[0066] Additionally or alternatively, in order to carry out the smoothing action, the effector can be configured in particular in such a way that repositioning and corresponding smoothing of the material layer can be carried out by lifting it and placing it again on a work table.

[0067] Additionally or alternatively, in order to carry out the smoothing action, the effector can be configured in particular such that a shaking movement can be carried out by means of the effector in order to achieve a smoothing of the material layer.

[0068] Additionally or alternatively, to carry out the smoothing action, the effector can have a blow-out unit for blowing out compressed air in the direction of the fabric layer, which is particularly configured such that compressed air can be blown onto the surface of a fabric layer in order to tension it to reduce wrinkles.

[0069] Additionally or alternatively, to carry out the smoothing action, the effector can have a smoothing plate, in particular a heatable smoothing plate, and can be configured such that smoothing can be carried out by pressing the smoothing plate onto the fabric layer.

[0070] Additionally or alternatively, to carry out the smoothing action, the effector can have an elastic and / or inflatable stamp (so-called fulling) and can be configured such that by pressing the stamp onto the fabric layer, the surface of the stamp can be enlarged, thus smoothing the fabric layer. Due to a friction surface between the stamp and the fabric layer, when the surface of the stamp is enlarged, the fabric layer spreads apart and wrinkles are reduced. According to a further exemplary embodiment, the system has a loosening unit for loosening the stack of fabric layers, wherein the loosening unit is arranged on a work table next to a stack of fabric layers and / or on the effector.The loosening unit comprises, for example, a shaking unit for shaking the stack of fabric layers, a compressed air unit for blowing compressed air into the side of the stack of fabric layers and / or an elastostatic unit for statically charging the fabric layers of the stack of fabric layers.

[0071] For example, the effector can press down on the stack of fabric layers and simultaneously loosen the stack of fabric layers using compressed air and / or a mechanical movement of the loosening unit, which can be stationary on the work table or mounted on the effector. The loosening unit can, for example, blow compressed air in, particularly from the sides, over the cut edges of the stack of fabric. Here, the smaller effector contour of the effector compared to the corresponding outer fabric layer contour is advantageous, as this leaves the edge zones free for loosening movement. Alternatively, a shaking mechanism can also loosen the stack of fabric. With stacks of fabric, this can be achieved using electromagnetic / electrostatic effects or compressed air flowing past the sides. Since electrostatic forces repel each other and / or compressed air flowing past creates a negative pressure, the topmost layer of fabric is loosened the most and thus prepared for separation.This further increases the reliability of the separation process. When such an auxiliary mechanism is mounted on the table instead of on the moving part of the robot, the robot has less weight to accelerate, resulting in a speed advantage.

[0072] According to a further exemplary embodiment, the system comprises a feed unit configured to convey a stack of fabric layers. The feed unit is configured to convey a stack of fabric layers from a storage area to a work table, at which fabric layers of the stack of fabric layers can be separated by means of the handling mechanism of the effector. The feed unit can, for example, comprise a conveyor belt and / or a manipulator (for example, another handling robot or a forklift truck) that conveys the stack of fabric layers from the storage area to the work table. The stack of fabric layers is automatically brought from a storage area into the work area of ​​the separation according to the invention.Since the singulation system can obtain sufficiently precise information about when a successful singulation process has been completed thanks to the additional monitoring of the singulation process, it can then predict when the next singulation process can take place (at the earliest). This is particularly important when changing fabric layer stacks, preventing breaks and waiting times, as the automatic feeding of another fabric layer stack from a storage area requires a certain lead time before the first fabric part from this fabric layer stack can be singulated.

[0073] According to another exemplary embodiment, the effector has a contact surface against which one of the fabric layers or stacks of fabric layers can be placed within the effector contour. This allows the fabric layer to be transported and later deposited without distortion or wrinkles.

[0074] In particular, this allows for the efficient reduction of wrinkles, and after placement, no mechanism for flattening is required. The contact surface forms, in particular, part of the handling mechanism for fixing one of the fabric layers or the stack of fabric layers, wherein the contact surface is designed to hold one of the fabric layers or the stack of fabric layers magnetically, based on air pressure, mechanically, or electrostatically to the effector. The contact surface allows the fabric layers or the stack of fabric layers to be transported and later deposited without distortion or wrinkles. After positioning or stacking the fabric layers, the fabric layers can be fixed more easily using the contact surface. The contact surface can, for example, be part of a magnetic device and be designed accordingly to be magnetic. Furthermore, the contact surface can be equipped with vacuum, with mechanical elements (e.g.Continuous microneedles) or electrostatic elements hold the fabric layers. According to another exemplary embodiment, the contact surface, as part of the handling mechanism, forms a suction surface to which one of the fabric layers or the stack of fabric layers can be applied.

[0075] According to a further exemplary embodiment, the system comprises a data processing unit configured to provide fabric layer data relating, in particular, to fabric layer material and / or fabric layer geometry. The data processing unit is further configured to provide processing data, in particular, to the left / right position, orientation, folds, and / or manufacturing quality of one of the fabric layers or of the fabric layer stack. Thus, the system can transfer information details regarding the placement of the fabric layers to a subsequent handling system for the next work step. This eliminates the need to re-record position details, material details, and / or left / right placement of the fabric layer. It has been shown that details regarding material properties, left / right position, location, folds, and / or manufacturing quality are particularly suitable for transfer.

[0076] In particular, the control unit, especially in conjunction with the data processing system, can use findings from sensory evaluation to determine whether the respective manipulation or handling was successful. This allows a change in reliability to be detected and communicated to a higher-level system. This can, for example, initiate preventive maintenance or an adjustment of the handling parameters.

[0077] According to a further exemplary embodiment, the effector has at least two, in particular different, handling mechanisms, wherein the two handling mechanisms have different handling mechanisms and / or apply different gripping intensities on the left and right side of one of the fabric layers or the fabric layer stack. The different handling mechanisms can, for example, have an electrostatic handling mechanism on the one hand and / or a vacuum-based handling mechanism (e.g. a suction device) on the other, which are controlled differently for singulation than for other manipulation steps. For example, only some of the existing vacuum suction cups of a suction device can be activated for singulation so that multiple fabric layers are not grasped, but afterwards all suction cups can be activated so that the fabric layer remains securely fixed during rapid position changes of the effector.The same principle can also be implemented in electrostatic / electromagnetic gripping systems of the handling mechanism by varying the total holding force of such a handling mechanism accordingly.

[0078] According to a further exemplary embodiment of the method, the effector is designed to wait more than 1 second, in particular more than 2 seconds, in particular more than 4 seconds, in particular more than 8 seconds, between two separations, in each of which a fabric layer is separated from the fabric layer stack using the handling mechanism, until the next separation from the same fabric layer stack. Picking up and handling a fabric layer from a fabric layer stack can lead to the fabric layers lying further down being lifted. It has been shown that by inserting a pause between two separations from the same fabric layer stack, the lifted layers can sink back down again.It has been shown that reliable separation of the desired fabric layers is achieved by waiting more than 1 second, in particular more than 2 seconds, preferably more than 4 seconds, and most preferably more than 8 seconds, before the next separation from the same fabric stack. The sinking back of the fabric layers can be assisted by suctioning the fabric layers in the fabric stack onto a work table on which the fabric layers in the fabric stack rest. The work table, for example, has suction openings so that the fabric layers can be sucked onto the work table using negative pressure. This can shorten the time between two separations.

[0079] It should be noted that the embodiments described here represent only a limited selection of possible embodiments of the invention. It is thus possible to combine the features of individual embodiments in a suitable manner, so that a multitude of different embodiments can be regarded as obviously disclosed by the embodiments explicitly described here. In particular, some embodiments of the invention are described with device claims, and other embodiments of the invention with method claims. However, upon reading this application, it will immediately become clear to the person skilled in the art that, unless explicitly stated otherwise, in addition to a combination of features belonging to one type of subject matter of the invention, any combination of features belonging to different types of subject matter of the invention is also possible. Brief Description of the Drawings

[0080] For further explanation and better understanding of the present invention, exemplary embodiments are described in more detail below with reference to the accompanying drawings. They show:

[0081] Fig. 1 shows a schematic representation of a system for handling fabric layers according to an exemplary embodiment.

[0082] Fig. 2 shows a schematic representation of an effector with a handling mechanism according to an exemplary embodiment.

[0083] Fig. 3 shows a schematic representation of a handling mechanism with a suction surface according to an exemplary embodiment of the present invention.

[0084] Fig. 4 shows a schematic representation of a system for handling and processing fabric layers with fixation elements arranged on the effector, according to an exemplary embodiment.

[0085] Fig. 5 shows a schematic representation of a system with an effector exchange device according to an exemplary embodiment.

[0086] Fig. 6 shows a schematic representation of a system with a roller unit for performing a smoothing action according to an exemplary embodiment.

[0087] Fig. 7 shows a schematic representation of a system with a blow-out unit for performing a smoothing action according to an exemplary embodiment. Fig. 8 shows a schematic representation of a system with a smoothing plate for performing a smoothing action according to an exemplary embodiment.

[0088] Fig. 9 shows a schematic representation of a system with a stamp for performing a smoothing action according to an exemplary embodiment.

[0089] Fig. 10 shows a schematic representation of a system with a loosening unit for supporting the separation of material layers according to an exemplary embodiment.

[0090] Detailed by exem

[0091] Identical or similar components in different figures are provided with the same reference numerals. The representations in the figures are schematic.

[0092] Fig. 1 shows a schematic representation of a system 100 for handling fabric layers 111 according to an exemplary embodiment. The system comprises a handling robot 100 with an effector 101 for handling fabric layers 111, wherein the effector 101 has a handling mechanism 120 configured to pick up and place at least one fabric layer 111. The handling mechanism 120 has an effector contour 106, wherein the fabric layer 111 can be fastened within the effector contour 106, wherein the effector contour 106 is smaller than an outer contour of the fabric layer 111. The handling mechanism 120 is configured to individually separate and pick up at least one fabric layer 111 from a fabric layer stack 112, to lay at least one separated fabric layer 111 flat on a work surface 102 of a work table 103, and to stretch the fabric layer 111 within the effector contour 106 without creases.Furthermore, the system comprises a monitoring device 130 which is configured to monitor the separation of the at least one fabric layer 111 from the fabric layer stack 112.

[0093] The handling mechanism 120 is configured to individually separate and pick up at least one fabric layer 111 from a fabric layer stack 112, wherein the handling mechanism 120 is further configured to lay at least one separated fabric layer 111 flat on a work surface 102 of a work table 103 and to stretch the fabric layer 111 within the effector contour 106 without creases.

[0094] Furthermore, the system has a monitoring device 130 which is configured to monitor the separation of the at least one fabric layer 111 from the fabric layer stack 112. In other words, the monitoring device 130 can monitor the process of separating the at least one fabric layer 111 and thus ensure whether, for example, the predetermined number, ie one or a specific number of fabric layers 111 are handled.

[0095] The handling robot 100 has the effector 101, to which the corresponding handling mechanism 120 is attached, in particular in an interchangeable manner. The handling robot 100 is fastened to the floor or to the work table 103 by a stationary robot base in order to introduce corresponding forces into the corresponding system. Alternatively, the handling robot 100 can also be configured such that the robot base is designed to be movable along the floor. A robot arm 104 can be arranged between the effector 101 and the robot base, which arm has, for example, one or more joints in order to control the effector 101 into a desired position. The controllable handling mechanism 120 is arranged on the effector 101. The handling mechanism 120 transports one or more fabric layers 111.The fabric layers 111 can be loosely placed on top of one another and gripped as a stack (for example, by means of negative pressure or by means of a mechanical gripper of the handling mechanism 120), or the fabric layers 111 can be fastened to one another, for example temporarily. The handling mechanism 120 can transport the fabric layers 111 to a joining unit 140. The effector 101 or the handling mechanism 120 can adapt to the contour of the fabric layers 111, for example, by adjusting the fixing points of the handling mechanism 120 to which the fabric layers 111 are fixed. For example, the fixing elements 401 described below, in which the individual fixing points are formed, can be arranged for this purpose. The handling mechanism 120 covers, in particular, the outline-relevant points of a contour of the fabric layer 111, wherein one edge of the fabric layers 111 preferably remains free as the joining area 113 and is not covered by the handling mechanism 120.The area of ​​the fabric layers 111 covered by the effector 101 or the handling mechanism 120 for securing the fabric layers 111 is referred to below as the effector contour 106. The effector 101 has a contact surface against which one of the fabric layers 111 or the fabric layer stack 112 can be placed within the effector contour 106. This allows the fabric layer 111 to be transported and later deposited without distortion or wrinkles.

[0096] The effector 101 thus forms an end part of the handling robot 100 with, for example, grippers as handling mechanism 120, which grasp and manipulate a fabric layer 111 (for example, a flat, unprocessed fabric layer 111 or an entire garment as a fabric layer 111) or a fabric layer stack 112 consisting of fabric layers 111 that are fastened with a fixing mechanism. The joining unit 140 is configured to process the joining areas of a fabric layer 111 and / or to join at least two fabric layers 111. The joining unit 140 can be a sewing machine, a welding machine, a tacking machine, a crocheting machine, an automatic gluing machine, or other automatic joining machines for fabric layers 111. The joining unit 140 can, for example, join two fabric layers 111 to one another, creating a seam (fabric seam or weld seam, etc.).The seam describes, for example, the connection of two layers of fabric 111 by means of a thread or yarn, wherein at least one material essentially represents a fabric, a fleece or a woven fabric.

[0097] According to the approach of the present invention, in particular, a monitoring device 130 is provided that monitors the separation of at least one fabric layer 111 or the plurality of fabric layers 111 from the fabric layer stack 112. This ensures that precise orientation of the fabric layers 111 and precise deposition of the fabric layers 111 are possible for subsequent further processing, for example, at the joining unit 140. In this case, the monitoring device 130 can also detect, in particular, the wrinkle-free state of the fabric layers 111 when they are picked up by the handling mechanism 120 within the effector contour 106.

[0098] The monitoring device 130 has an optical sensor 131, in particular a monitoring camera. The optical sensor 131 is configured to detect an isolated fabric layer 111 that has been picked up by the handling mechanism 120. Using an optical sensor 131, e.g., a camera, and suitable downstream evaluation, both the pick-up in the fabric layer 111 and the crease-free positioning after laying down can be ensured.

[0099] Furthermore, the monitoring device 130 has a weight sensor 132, wherein the weight sensor 132 is arranged on the effector 101 such that a weight of the fabric layer 111 picked up by the handling mechanism 120 can be measured. Additionally or alternatively, a weight sensor 403 is installed in the work table 103 (see Fig. 4) and configured such that a change in the weight of the fabric layer stack 112 can be measured before and after the separation of a fabric layer 111.

[0100] Furthermore, the monitoring device 130 has a distance sensor 133 to determine the presence of an isolated fabric layer 111 on the handling mechanism 120. By means of the distance sensor, the monitoring device 130 can monitor the presence of a fabric layer 111 held by the handling mechanism 120 and, for example, also the thickness of the fabric layers 111 or the total thickness of the fabric layers 111 on the effector 101.

[0101] In the embodiment of Fig. 1, the handling mechanism 120 comprises a suction device 121 configured to separate and pick up a fabric layer 111 from the fabric layer stack 112 using negative pressure. The monitoring device 130 comprises, for example, a vacuum sensor configured to measure an air flow of the suction device 121, wherein the air flow is indicative of whether the suction device 121 is holding a fabric layer 111, whether multiple fabric layers 111 are being held, or whether no fabric layer 111 is being picked up.

[0102] The suction device 121 comprises, for example, at least one suction device, wherein the suction device 121 is designed to suck air from at least one fabric layer 111 to be held by means of the suction device such that the fabric layers 111 can be fixed to the suction device 121. Since the fabric layers 111 are permeable to air to a certain extent due to their material properties, one, two, or more fabric layers 111 in a fabric layer stack 112 can be secured by suction with an appropriately adjusted suction power. The suction device 121 comprises, for example, a vacuum pump, which can be arranged at a distance from the effector 101, for example, on the work table 103. One or more suction devices, such as suction cups, can be attached to the effector 101 as part of the handling mechanism 120. Furthermore, the suction device 121, together with the suction devices, can also form parts of the handling mechanism 120 in order to align and transport the fixed fabric layers 111.In an exemplary embodiment, the suction device 121 also forms parts of the handling mechanism 120 for handling the fabric layers 111.

[0103] The handling mechanism 120 is, for example, selected from the group consisting of grippers, suction cups, clamps, areas with increased friction and / or electrostatic attraction, holding needles, rollers, freezing grippers, and / or Bernoulli grippers.

[0104] The handling mechanism 120 can be controlled in particular by the control unit 105 such that different gripping intensities for fixing one of the fabric layers 111 or several fabric layers 111 can be controlled.

[0105] The monitoring device 130 generates monitoring data describing the number, orientation, and / or condition of the material layer 111 fixed to the handling mechanism 120, wherein the handling mechanism 120 can be controlled based on the monitoring data. The monitoring data can be acquired and monitored, for example, using sensors 131, 132, 133. The data is processed, for example, in the control unit 105. The control unit 105 can further be configured to control the handling robot 100 and, in particular, the handling mechanism 120.

[0106] The control unit 105 is thus designed to control the handling robot 100 and / or the joining unit 140. The control unit 105 is configured to collect and evaluate the data relating to the movement of the effector 101 and the joining result of the joining unit 140, and in particular the monitoring data, in order to take measures relating to the control of the movement of the effector 101 and the joining process of the joining unit 140 in the event of a predetermined deviation from a predeterminable limit value. The control unit 105 can be coupled wirelessly or by cable to the individual sensors of the system in order to receive the corresponding movement data, position data, and status data of the effector 101, as well as the data of the joining unit 140, as well as the status data of the joining point or the joining result of the fabric part.

[0107] The system further comprises a feed unit 107 configured to transport a fabric layer stack 112. The feed unit 107 is configured to transport a fabric layer stack 112 from a storage area to a work table 103, at which fabric layers 111 of the fabric layer stack 112 can be separated by means of the handling mechanism 120 of the effector 101. The feed unit 107 can comprise, for example, a conveyor belt and / or a manipulator (for example, another handling robot 100 or a forklift truck) that transports the fabric layer stack 112 from the storage area to the work table 103.

[0108] Fig. 2 shows a schematic representation of an effector 101 with a handling mechanism 120 according to an exemplary embodiment. The effector 101 has at least two, in particular different, handling mechanisms 120, wherein the two handling mechanisms 120 have different handling mechanisms and / or apply different gripping intensities on the left and right sides of one of the fabric layers 111 or the fabric layer stack 112. For example, the effector 101 has a suction device 121 and a holding needle device 201. The suction device 121 and the holding needle device 201 can be selectively controlled to fix one of the fabric layers 111 or the fabric layer stack 112.

[0109] The holding needle device 201 has holding needles 202 which are configured such that a penetration depth and / or a penetration angle of at least one holding needle 202 is controllable. The holding needle device 201 is designed to introduce holding needles 202 into the fabric layers 111 for fixation. By means of the holding needle device 201, one or more needle-like pins or holding needles can be driven from a magazine into or through the fabric layers 111 either from the effector side, from the work table side, or from an auxiliary system (e.g., auxiliary plate, needle belt) in order to fasten them to one another and / or to the effector 101. The holding needle device 201 has, in particular, a feed device, for example, a holding needle magazine, which is configured to feed holding needles for the holding needle device.

[0110] Fig. 3 shows a schematic representation of a handling mechanism 120 with a suction surface 301 according to an exemplary embodiment of the present invention. In particular, the suction device 121 forms the suction surface 301, against which one of the fabric layers 111 or the fabric layer stack 112 can be applied. This surface 301 thus forms the effector contour 106. The suction surface 301 has a plurality of suction openings 302. With a handling mechanism 120 based on negative pressure, sufficient force can only be generated with a high negative pressure and a small suction opening to hold the fabric layers 111.

[0111] Fig. 4 shows a schematic representation of a system for handling and processing fabric layers 111 with fixing elements 401 arranged on the effector 101, according to an exemplary embodiment. The fixing elements 401 can be arranged pivotably and extendably on the effector 101. The handling mechanism 120 can be arranged on one of the fixing elements 401, wherein the handling mechanism 120 is further configured to fix and transport the fabric layer stack 112 for handling to the joining unit 140, in particular within the effector contour 106.

[0112] The effector 101 can have several, e.g., five, fixation elements 401. A fixation element 401 has at least one handling mechanism 120, for example, a suction device 121, a mechanical gripper, grippers with vacuum nozzles, a holding needle device 201 with holding needles 202, a fixation system with electrostatic attraction, fixation rollers, in particular counter-rotating fixation rollers, and / or clamps.

[0113] A plurality of fixation points with corresponding (identical or different) handling mechanisms 120 can be arranged on a support rod of a fixation element 401. The support rod can, in particular, be pivotably and / or translationally displaceably attached to the effector 101. Furthermore, the support rod can, for example, be telescopically extendable and retractable in order to change its length. In addition, the support rod itself can have at least one joint, so that the support rod itself has two pivotable sub-regions. This enables precise adjustment and setting of the gripping device of a fixation element 401. The adjustment of the effector contour 106 of the effector 101 can be enabled, for example, by integrated actuators (e.g., stepper motors with mechanical transmission to the fixation elements 401).

[0114] The fixing elements 401 are arranged on the effector 101 such that at least one fixing element 401 or all guide elements 401 have two degrees of freedom per arm in an xy-plane and in particular a further additional degree of freedom in the z-plane (for folding away inactive grippers).

[0115] The xy plane is defined as the plane in which the material layer 111 is located when it is fixed by the fixing elements. Specifically, the material layer 111 is spanned between the fixing elements. In this spanned state, the material layer 111 has a flat shape and thus lies within the xy plane. The normal to the xy plane forms the z direction. In other words, the xy plane forms the material plane, and the thickness of the material is defined along the z direction.

[0116] According to a further exemplary embodiment, the handling mechanism 120 is configured to grasp a fabric layer 111 at fixing points to which the handling mechanism 120 fixes the fabric layer 111. The handling mechanism 120 is further configured such that the fixed fabric layer 111 can be tensioned by moving the fixing points. Additionally or alternatively, the handling mechanism 120 is further configured to fix the fabric layer 111 at additional fixing points within the effector contour 106 and / or to re-tension it using the additional fixing points. By moving the fixing elements 401, for example, a fixing point can then be moved, thus enabling the held fabric layers 111 to be tensioned accordingly.

[0117] Furthermore, a data processing unit 402 is shown, which is configured to provide fabric layer data relating, in particular, to fabric layer material and / or fabric layer geometry. The data processing unit 402 is further configured to provide processing data, in particular, the left / right position, orientation, folds, and / or manufacturing quality of one of the fabric layers 111 or the fabric layer stack 112. The data processing unit 402 is coupled to the control unit 105 for data exchange. In particular, the control unit 105, particularly in conjunction with the data processing system 402, can use the findings from the sensory evaluation to determine whether the respective manipulation or handling was successful.

[0118] Fig. 5 shows a schematic representation of a system with an effector exchange device 501 according to an exemplary embodiment. The effector 101 is designed to be exchangeable. The system can have an effector exchange device 501 which is designed to automatically couple and decouple an effector 101 from the handling robot 100. The effector exchange device 501 is designed, in particular, to automatically couple and decouple supply lines to the effector 101. The effector exchange device 501 is further configured to transport the effector 101 between a storage location 503 and the handling robot 100. The effector 101 can thus be deposited at a location, and another effector 101 can be coupled to the handling robot 100. In this case, the required connections to resources (energy, compressed air, vacuum, data, control lines) are also connected, and dust tightness is ensured.In this way, the contour issue can be solved for pieces of fabric of different sizes.

[0119] The effector exchange device 501 is arranged, for example, at a storage location 503 where a plurality of different effectors with different handling mechanisms can be stored. The handling robot 100 can place the effector 101 at a predetermined location on the effector exchange device 501 by moving its robot arm 104. The effector exchange device 501 can be arranged locally at the storage location 503 to receive the effector 101. For example, automatic coupling and decoupling can take place on the robot arm 104 to place the effector 101 at a desired location on the effector exchange device 501. The system can, in particular, have an effector cleaning system 504 at the storage location 503 to clean the effector 101. At the storage location 503, the unused effector 101 can be (automatically) cleaned using the effector cleaning system 504.In particular, surfaces with specific frictional resistance require regular cleaning to ensure the desired friction effects. Furthermore, the effector cleaning system 504 can be used to clean sensors, such as optical lenses of the optical sensor 131, or parts of the suction device 121 or the vacuum system.

[0120] Furthermore, the work table 103 has a hold-down device 505, which is configured to selectively fix the fabric layer 111 to the work table 103, in particular by means of electrostatic holding forces. The hold-down device 505 can press with a force against the work table 103 / the work surface 102, which leads to a fixation of the two intermediate fabric layers 111. Alternatively, the effector 101 can also allow compressed air to flow between its underside and the fabric layers 111. This is particularly helpful when the effector 101 needs to reposition itself so that it can quickly overcome the adhesive forces between the effector 101 and the first fabric layer 111.

[0121] Fig. 6 shows a schematic representation of a system with a roller unit 601 for performing a smoothing action according to an exemplary embodiment. If a fold is detected by the monitoring device 130, such a smoothing action of the fabric layer 111 can be performed. To perform the smoothing action, the effector 101 is configured in particular such that the effector 101 places the fabric layer 111 on a work table 103 and changes the fixing points of the handling mechanism 120 with the fabric layer 111, so that the fabric layer 111 can be smoothed out. Additionally or alternatively, to perform the smoothing action, the effector 101 can be configured in particular such that the fabric layer 111 can be repositioned and accordingly smoothed by lifting it and placing it again on a work table 103.Furthermore, in order to carry out the smoothing action, the effector 101 can be configured in particular such that a shaking movement can be carried out by means of the effector 101 in order to achieve a smoothing of the material layer 111.

[0122] As shown in Fig. 6, to carry out the smoothing action, the effector 101 can have a roller unit 601, in particular configured such that the effector 101 places the fabric layer 111 on a work table 103 and smooths the fabric layer 111 by means of the roller unit 601.

[0123] Fig. 7 shows a schematic representation of a system with a blow-out unit 701 for performing a smoothing action according to an exemplary embodiment. To perform the smoothing action, the effector 101 can have a blow-out unit 701 for blowing compressed air toward the fabric layer 111, which is configured in particular such that compressed air can be blown onto the surface of a fabric layer 111 in order to tension it to reduce wrinkles.

[0124] Fig. 8 shows a schematic representation of a system with a smoothing plate 801 for performing a smoothing action according to an exemplary embodiment. To perform the smoothing action, the effector 101 can have a smoothing plate 801, in particular a heatable smoothing plate 801, and can be configured such that smoothing can be performed by pressing the smoothing plate 801 onto the fabric layer 111.

[0125] Fig. 9 shows a schematic representation of a system with a stamp 901 for performing a smoothing action according to an exemplary embodiment. To perform the smoothing action, the effector 101 may have an elastic and / or inflatable stamp 901 and be configured such that by pressing the stamp 901 onto the fabric layer

[0126] 111 the surface of the stamp 901 can be enlarged and thus a smoothing of the material layer 111 can be carried out.

[0127] Fig. 10 shows a schematic representation of a system with a loosening unit 1001 for supporting the separation of fabric layers 111 according to an exemplary embodiment. The loosening unit 1001 is arranged on a work table 103 next to a fabric layer stack 112 and / or on the effector 101. In the illustrated embodiment, the loosening unit 1001 has a compressed air unit for blowing compressed air laterally into the fabric layer stack.

[0128] 112 on.

[0129] For example, the effector 101 can press on the fabric layer stack 112 and simultaneously loosen the fabric layer stack 112 with compressed air and / or a mechanical movement of the loosening unit 1001, which is stationary and mounted on the work table 103. In this case, the loosening unit 1001 can, for example, blow compressed air in, particularly laterally, over the cut edges of the fabric layer stack 112.

[0130] Additionally, it should be noted that "comprising" does not exclude other elements or steps, and "a" or "an" does not exclude a plurality. Furthermore, it should be noted that features or steps described with reference to one of the above embodiments may also be used in combination with other features or steps of other embodiments described above. Reference symbols in the claims are not to be considered as limiting. List of reference symbols:

[0131] 100 Handling robot 401 Fixing element

[0132] 101 Effector 402 Data processing unit

[0133] 102 Work surface 403 Weight sensor work table

[0134] 103 Work table

[0135] 104 Robot arm 501 Effector exchange device

[0136] 105 Control unit 502 additional effector

[0137] 106 Effector contour 503 Storage location

[0138] 107 Feed unit 504 Effector cleaning system

[0139] 505 hold-down device

[0140] 111 layers of fabric

[0141] 112 fabric layer stacks 601 roll unit

[0142] 113 Joining area

[0143] 701 Blow-out unit

[0144] 120 Handling mechanics

[0145] 121 Suction device 801 Smoothing plate

[0146] 130 Monitoring device 901 Stamp

[0147] 131 optical sensor

[0148] 132 Weight sensor 1001 Loosening unit

[0149] 133 Distance sensor

[0150] 140 joining unit

[0151] 201 Holding needle device

[0152] 202 holding pins

[0153] 301 suction surface

[0154] 302 intake opening

Claims

Patent claims 1. A system for handling and processing fabric layers (111), the system comprising a handling robot (100) with an effector (101) for handling fabric layers (111), wherein the effector (101) has a handling mechanism (120) designed to pick up and place at least one fabric layer (111), wherein the handling mechanism (120) has an effector contour (106), wherein the fabric layer (111) can be fastened within the effector contour (106), wherein the effector contour (106) is smaller than an outer contour of the fabric layer (111), wherein the handling mechanism (120) is configured to individually separate and pick up at least one fabric layer (111) from a fabric layer stack (112), wherein the handling mechanism (120) is further configured to place at least one separated fabric layer (111) on a work surface (102) a work table (103), wherein the handling mechanism (120) is further configured such thatto stretch the fabric layer (111) within the effector contour (106) without creases, and a monitoring device (130) which is configured to monitor the separation of the at least one fabric layer (111) from the fabric layer stack (112).

2. System according to claim 1, wherein the monitoring device (130) comprises an optical sensor (131), in particular a monitoring camera, wherein the optical sensor (131) is configured to detect an isolated layer of material (111) which is picked up by the handling mechanism (120).

3. System according to claim 1 or 2, wherein the monitoring device (130) has a weight sensor (132), wherein the weight sensor (132) is arranged on the effector (101) such that a weight of the fabric layer (111) picked up by the handling mechanism (120) can be measured, and / or wherein the weight sensor (132) is configured such that a change in the weight of the fabric layer stack before and after the separation of a fabric layer (111) can be measured.

4. System according to one of claims 1 to 3, wherein the monitoring device (130) comprises a tactile sensor and / or a distance sensor (133) to determine the presence of an isolated fabric layer (111) on the handling mechanism (120).

5. System according to one of claims 1 to 4, wherein the handling mechanism (120) comprises a suction device (121) which is configured to separate and pick up a fabric layer (111) from the fabric layer stack (112) by means of negative pressure, wherein the monitoring device (130) in particular comprises a vacuum sensor which is configured to measure an air flow of the suction device (121), wherein the air flow is indicative of whether the suction device (121) is holding a fabric layer (111), whether several fabric layers are held or whether no fabric layer (111) is picked up.

6. System according to claim 5, wherein the suction device (121) forms a suction surface (301) to which one of the fabric layers (111) or the fabric layer stack (112) can be applied, wherein the suction surface (301) has a plurality of suction openings (302), in particular more than 9, more than 15, more than 22 and / or more than 30 suction openings (302).

7. System according to claim 6, wherein the suction openings (302) are formed with a diameter of less than 20 mm, in particular less than 10 mm, further in particular less than 5 mm, further in particular less than 3 mm.

8. System according to one of claims 1 to 7, wherein the monitoring device (130) comprises a sensor for measuring an electromagnetic field, wherein the electromagnetic field strength is indicative of whether the handling mechanism (120) is holding a layer of fabric (111), whether several layers of fabric are held, or whether no layer of fabric (111) is picked up.

9. System according to one of claims 1 to 8, wherein the handling mechanism (120) is configured to grasp a fabric layer (111) at fixing points to which the handling mechanism (120) fixes the fabric layer (111), wherein the handling mechanism (120) is further configured such that the fixed fabric layer (111) can be tensioned by moving the fixing points, and / or wherein the handling mechanism (120) is further configured to fix the fabric layer (111) at further fixing points within the effector contour (106) and / or to re-tension it with the further fixing points.

10. System according to one of claims 1 to 9, wherein the handling mechanism (120) is further configured such that fabric layers (111) can be picked up individually from two spaced-apart fabric layer stacks (112).

11. System according to one of claims 1 to 10, wherein the effector (101) has at least one fixing element (401) on which the handling mechanism (120) is formed, wherein the handling mechanism (120) is further designed to fix and convey the fabric layer stack (112) for handling to a joining unit, in particular within the effector contour (106), wherein the handling mechanism (120) is selected from the group consisting of grippers, suction cups, clamps, areas with increased friction and / or electrostatic attraction, holding needles (202), rollers, freezing grippers, and / or Bernoulli grippers.

12. System according to one of claims 1 to 11, wherein the handling mechanism (120) is controllable such that different gripping intensities for fixing one of the fabric layers (111) or several fabric layers (111) are controllable.

13. System according to one of claims 1 to 12, wherein the effector (101) has at least two handling mechanisms which are selectively controllable for fixing one of the fabric layers (111) or the fabric layer stack, wherein the at least two handling mechanisms are activatable and controllable in particular in a location-dependent manner, depending on a sensor value, depending on a manipulation step and / or a joining step.

14. System according to one of claims 1 to 13, wherein the monitoring device (130) generates monitoring data which describe the number, the orientation and / or the nature of the material layer (111) which is fixed to the handling mechanism (120), wherein the handling mechanism (120) is controllable based on the monitoring data.

15. System according to one of claims 1 to 14, wherein the handling mechanism (120) comprises a holding needle device (201) with holding needles (202), which is configured such that a piercing depth and / or a piercing angle of at least one holding needle (202) is controllable, in particular in real time and / or based on sensor feedback.

16. System according to claim 15, wherein the holding needles (202) have a diameter of less than 1300 micrometers, less than 900 micrometers, in particular less than 550 micrometers, further in particular less than 250 micrometers.

17. System according to one of claims 1 to 16, wherein the handling mechanism (120) has a support element, in particular a support plate, for placing the at least one fabric layer (111) to be conveyed, wherein the handling mechanism (120) is in particular configured such that the fabric layer (111) can be lifted and the support element can be conveyed under the fixed fabric layer (111).

18. System according to one of claims 1 to 17, wherein the handling mechanism (120) is designed such that a joining region (113) of the material layer (111), at which a joining step of a joining unit (140) can be carried out, has a Overhang of more than 0.5 cm, in particular more than 1 cm, further in particular more than 2 cm or more than 3 cm.

19. System according to one of claims 1 to 18, further comprising the work table (103) with the work surface (102), wherein the work table (103) has a hold-down device (505) which is configured to selectively fix the fabric layer (111) to the work table (103), in particular by means of electrostatic holding forces.

20. System according to one of claims 1 to 19, wherein the monitoring device comprises a humidity sensor, wherein the handling mechanism, which is designed in particular as an electrostatic handling mechanism (120), is controllable based on the measured humidity, wherein the system in particular comprises an air humidification device for adjusting the humidity, wherein the air humidification device is controllable based on the measured humidity.

21. System according to one of claims 1 to 20, wherein the monitoring device is configured to detect misgripping or misplacement of the material layer (111) on the handling mechanism (120), wherein the handling mechanism is configured to deposit the material layer (111) and re-grip it upon detection of misgripping or misplacement.

22. System according to one of claims 1 to 21, wherein the effector (101) is designed to be replaceable, wherein the system in particular comprises an effector exchange device (501) which is designed to automatically couple and uncouple an effector (101) from the handling robot (100), wherein the effector exchange device (501) is in particular designed to automatically couple and uncouple supply lines to the effector (101), wherein the effector exchange device (501) is configured to transport the effector (101) between a storage location (503) and the handling robot (100), wherein the system in particular comprises an effector cleaning system (504) at the storage location (503) in order to clean the effector (101).

23. System according to one of claims 1 to 22, wherein the effector (101) is designed to press down the fabric layer (111) on a work surface (102) of a work table (103).

24. System according to one of claims 1 to 23, wherein the effector (101) is configured, in particular upon detection of a fold by means of the monitoring device (130), to carry out a smoothing action of the fabric layer (111), wherein to carry out the smoothing action the effector (101) is configured in particular such that the effector (101) places the fabric layer (111) on a work table (103) and changes fixing points of the handling mechanism (120) with the fabric layer (111) so that a smoothing of the fabric layer (111) can be carried out, wherein to carry out the smoothing action the effector (101) has a roller unit (601), which is configured in particular such that the effector (101) places the fabric layer (111) on a work table (103) and smooths the fabric layer (111) by means of the roller unit (601), wherein to carry out the smoothing action of the effector (101) is configured in particular such that by lifting and placing it again on a work table (103) a repositioning and corresponding smoothing of the fabric layer (111) can be carried out, wherein to carry out the smoothing action the effector (101) is in particular configured such that by means of which the effector (101) a shaking movement can be carried out in order to achieve a smoothing of the fabric layer (111), wherein to carry out the smoothing action the effector (101) has a blow-out unit (701) for blowing out compressed air in the direction of the fabric layer (111) and is in particular configured such that compressed air can be blown onto the surface of a fabric layer (111) in order to tension it to reduce wrinkles, wherein to carry out the smoothing action the effector (101) has a smoothing plate (801), in particular a heatable smoothing plate (801), and is configured such that by pressing the smoothing plate (801) onto the smoothing can be carried out on the material layer (111),and / or wherein, to carry out the smoothing action, the effector (101) has an elastic and / or inflatable stamp (901) and is configured such that by pressing the stamp (901) onto the fabric layer (111), the surface of the stamp (901) can be enlarged and thus a smoothing of the fabric layer (111) can be carried out., 25. System according to one of claims 1 to 24, further comprising a loosening unit (1001) for loosening the fabric layer stack, wherein the loosening unit (1001) is arranged on a work table (103) next to a fabric layer stack (112) and / or on the effector (101), wherein the loosening unit (1001) has a shaking unit for shaking the fabric layer stack, a compressed air unit for blowing compressed air laterally into the fabric layer stack (112) and / or an elastostatic unit for statically charging the fabric layers (111) of the fabric layer stack.

26. System according to one of claims 1 to 25, further comprising a feed unit (107) configured to convey a Fabric layer stack, wherein the feed unit (107) is configured to convey a fabric layer stack (112) from a storage area to a work table (103), at which fabric layers (111) of the fabric layer stack can be separated by means of the handling mechanism (120) of the effector (101).

27. System according to one of claims 1 to 26, wherein the effector (101) has a contact surface which can be applied to one of the fabric layers (111) or the fabric layer stack (112) within the effector contour (106).

28. System according to one of claims 1 to 27, further comprising a data processing unit (402) which is configured To provide fabric layer data relating in particular to fabric layer material and / or fabric layer geometry, wherein the data processing unit (402) is further configured to provide processing data, in particular left / right position, orientation, folds and / or manufacturing quality of one of the fabric layers (111) or of the fabric layer stack.

29. System according to one of claims 1 to 28, wherein the effector (101) has at least two, in particular different, handling mechanisms, wherein the two handling mechanisms have different handling mechanisms and / or apply different gripping intensities on the left and right side of one of the fabric layers (111) or the fabric layer stack.

30. System according to one of claims 1 to 29, wherein the fabric layers (111) and / or the fabric layer stack (112) represent a garment or parts thereof.

31. Method for handling and processing layers of material (111), the method comprising Picking up and placing down at least one fabric layer (111) by means of a handling mechanism (120) of an effector (101) of a handling robot (100), wherein the handling mechanism (120) has an effector contour (106), wherein the fabric layer (111) can be fastened within the effector contour (106), wherein the effector contour (106) is smaller than an outer contour of the fabric layer (111), wherein the handling mechanism (120) is configured to individually separate and pick up at least one fabric layer (111) from a fabric layer stack (112), wherein the handling mechanism (120) is further configured to place at least one separated fabric layer (111) flat on a work surface (102) of a work table (103), wrinkle-free stretching of the fabric layer (111) within the effector contour (106), and Monitoring the separation of the at least one fabric layer (111) from the fabric layer stack (112) by means of a monitoring device (130).

32. Method according to claim 31, wherein the effector (101) is designed to wait more than 1 second, in particular more than 2 seconds, in particular more than 4 seconds, in particular more than 8 seconds, between two separations, in each of which a fabric layer (111) is separated from the fabric layer stack (112) by the handling mechanism (120), until the next separation from the same fabric layer stack (112).

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