ADJUSTABLE SEWING CELL FUNCTION

Abstract

A robotic sewing assembly is provided. The robotic sewing assembly includes a support for supporting the article being sewn and a robotic arm. The robotic arm includes a sewing head. The sewing head is configured to apply stitches to the article. The robotic arm is configured to manipulate the sewing head in multiple directions relative to the article. The support includes a servo unit to which the article is connected and which is configured to manipulate the article in multiple directions relative to the sewing head. The robotic arm, the sewing head, and the servo unit may operate in concert. [Fig.2A]

Description

Title of the invention: ADJUSTABLE FUNCTION OF SEWING CELL

[0001] REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 571,770 filed on March 29, 2024.

[0003] BACKGROUND

[0004] Exemplary embodiments of the present disclosure relate to the art of robotic sewing assemblies for use in sewing processes.

[0005] Robotic sewing technology often includes a sewing head. The sewing head may include an upper arm and a lower arm and may be attached to a robotic arm. The robotic arm positions the sewing head proximate the article to be sewn. The article, which may be, but need not be, an instrument panel (IP) of an automobile, for example, is typically held in place by a bracket. The robotic arm orients the sewing head so that a given stitching operation can be performed relative to the article.

[0006] SUMMARY

[0007] According to one aspect of the disclosure, a robotic sewing assembly is provided. The robotic sewing assembly includes a support for supporting an article being sewn and a robotic arm. The robotic arm includes a sewing head. The sewing head is configured to apply stitches to the article. The robotic arm is configured to manipulate the sewing head in multiple directions relative to the article. The support includes a servo unit to which the article is connected and which is configured to manipulate the article in multiple directions relative to the sewing head. The robotic arm, the sewing head, and the servo unit may operate in concert.

[0008] According to additional and / or alternative embodiments, the robotic arm comprises a first arm rotatable in at least one direction, a second arm rotatably attached to the first arm for rotation in at least one direction, and a coupling by which the sewing head is rotatably attached to the second arm for rotation in at least two directions.

[0009] According to additional and / or alternative embodiments, the sewing head comprises a sewing needle and a needle plate.

[0010] According to additional and / or alternative embodiments, the support further comprises a frame to which the servo unit is attached and a vertically oriented screen plate supported on the frame proximate the servo unit.

[0011] According to additional and / or alternative embodiments, the servo unit is configured to manipulate the article in multiple directions relative to the sewing head during sewing.

[0012] According to additional and / or alternative embodiments, the servo unit is configured to rotate and translate the article about and along multiple axes.

[0013] According to additional and / or alternative embodiments, the servo unit is configured to rotate the article about a longitudinal axis of the article, to raise and lower the article, and to drive the article laterally in first and second transverse directions.

[0014] According to additional and / or alternative embodiments, the robotic sewing assembly further comprises a programmable logic controller for controlling the robotic arm, the sewing head and the servo unit to operate in concert with each other and without operator intervention.

[0015] According to one aspect of the disclosure, a robotic sewing assembly is provided for sewing an instrument panel (IP) comprising an elongated flattened section and an elongated curved section defining vents. The robotic sewing assembly comprises a support for supporting the IP and a robotic arm. The robotic arm comprises a sewing head. The sewing head is configured to apply stitches to the IP. The robotic arm is configured to manipulate the sewing head in multiple directions relative to the IP. The support comprises a servo unit to which the IP is connected and which is configured to manipulate the IP in multiple directions relative to the sewing head. The robotic arm, the sewing head and the servo unit may operate in concert to perform sewing on the elongated flattened section and the elongated curved section defining the vents of the IP.

[0016] According to additional and / or alternative embodiments, the robotic arm comprises a first arm rotatable in at least one direction, a second arm rotatably attached to the first arm for rotation in at least one direction, and a coupling by which the sewing head is rotatably attached to the second arm for rotation in at least two directions.

[0017] According to additional and / or alternative embodiments, the sewing head comprises a sewing needle and a needle plate.

[0018] According to additional and / or alternative embodiments, the support further comprises a frame to which the servo unit is attached and a vertically oriented shield plate supported on the frame proximate the servo unit.

[0019] According to additional and / or alternative embodiments, the servo unit is configured to manipulate the IP in multiple directions relative to the sewing head during sewing.

[0020] According to additional and / or alternative embodiments, the servo unit is configured to rotate and translate the IP about and along multiple axes during sewing.

[0021] According to additional and / or alternative embodiments, the servo unit is configured to rotate the IP about a longitudinal axis of the article, to raise and lower the IP, and to drive the IP laterally in first and second transverse directions during sewing.

[0022] According to additional and / or alternative embodiments, the stitching is performed along multiple exterior and bottom faces of the IP at the elongated flattened section, the elongated curved section, and one or more of the vents.

[0023] According to additional and / or alternative embodiments, the robotic sewing assembly further comprises a programmable logic controller for controlling the robotic arm, the sewing head and the servo unit to operate in concert with each other to perform sewing on the elongated flattened section and the elongated curved section defining the vents of the IP and without operator intervention.

[0024] According to one aspect of the disclosure, a method of operating a robotic sewing assembly for sewing an article is provided. The method includes providing a robotic arm including a sewing head and providing a support, connecting a servo unit of the support to the article, and sewing along multiple exterior and underside faces of the article. Sewing simultaneously includes controlling the robotic arm to manipulate the sewing head relative to the article, controlling the sewing head to apply stitches to the article, and controlling the servo unit to rotate the article about a longitudinal axis of the article, to raise and lower the article, and to drive the article laterally in first and second transverse directions.

[0025] According to additional and / or alternative embodiments, the method is executable by a programmable logic controller without operator intervention.

[0026] According to additional and / or alternative embodiments, the article is an instrument panel (IP) of an automobile and includes an elongated flattened section, an elongated curved section and one or more vents and the stitching is executed along multiple exterior and lower faces of the IP at the elongated flattened section, the elongated curved section and the one or more vents.

[0027] Additional features and advantages are realized by the techniques described in the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered part of the claimed technical concept. For a better understanding of the disclosure, of its advantages and characteristics, reference should be made to the description and drawings. Brief description of the drawings

[0028] For a more complete understanding of this disclosure, reference is now made to the following brief description, taken in conjunction with the accompanying drawings and detailed description, where like reference numerals represent like parts:

[0029] [Fig. 1] is a perspective view of an article, such as an instrument panel (IP) of an automobile, to be sewn in accordance with embodiments;

[0030] [Fig.2A] and [Fig.2B] are schematic perspective and side views, respectively, of a robotic sewing assembly for performing sewing of the article of [Fig.l] in accordance with embodiments;

[0031] [Fig.3] is a schematic diagram of a programmable controller of the set robotic sewing of [Fig.2A] and 2B according to embodiments;

[0032] [Fig.4] is a graphical illustration of a sequence of operations of the set of robotic sewing of [Fig.2A] and 2B in accordance with embodiments; and

[0033] [Fig.5] is a flowchart illustrating a method of operating a set robotic sewing for sewing an article, such as an instrument panel (IP) of an automobile, according to embodiments. DETAILED DESCRIPTION

[0034] A detailed description of one or more embodiments of the disclosed apparatus and method is presented herein by way of example and not limitation with reference to the Figures.

[0035] In most cases, a support allows a robotic sewing assembly to access a location on a part or article being sewn where a stitch is to be applied. However, some part configurations prevent access to all stitch locations on the part without reaching the boundaries of the robotic sewing assembly. For example, access to locations near the top of an instrument panel (IP) and the bottom of an instrument panel (IP) may be difficult in designs where such access is limited to the top or bottom.

[0036] Thus, as described below, a carrier is provided that is capable of adjusting the position and / or orientation of a part or article being sewn relative to a robotic sewing assembly. Complete production of the part or article can thus be achieved more quickly and efficiently. The part or article is affixed to the carrier and the carrier is capable of controlling the position and / or orientation of the part or article in real time to allow the sewing head of a robotic sewing assembly to access all the locations of sewing of the part or article during the sewing process. This allows the sewing head to access hard-to-reach areas on some parts or articles with particularly complex geometries. The support is capable of moving the part or article in a variety of ways, including, but not limited to, rotating the part or article around a given axis and moving the part or article up, down, or sideways.

[0037] With reference to [Fig. 1] and [Fig. 2A] and 2B, a robotic sewing assembly 201 is provided for sewing an article, such as an IP 101 for an automobile (for clarity and brevity, the following description will generally refer to the IP 101, but it is to be understood that this terminology is and would be interchangeable with the "article"). The IP includes an elongated flattened section 110 and an elongated curved section 120 that is shaped to define one or more vents 121. Sewing the IP 101 adds stitches to multiple exterior and bottom faces of the IP 101 at the elongated flattened section 110, at the elongated curved section 120, and at edges of one or more vents 121.

[0038] The robotic sewing assembly 201 includes a support 210 for rotatably and movably supporting the IP 101 and a robotic arm 220. The robotic arm 220 includes a sewing head 230. The sewing head 230 is configured to apply stitches to the multiple outer and lower faces of the IP 101 at the elongated flattened section 110, at the elongated curved section 120, and at edges of one or more vents 121. The robotic arm 220 is configured to manipulate the sewing head 230 in multiple directions relative to the IP 101. The support 210 includes an optional base portion 211 to which the robotic arm 220 may be anchored (although it is understood that, in a robotic gantry system for example or other similar cases, no anchoring is not necessary or planned) and a servo unit 212 to which the IP 101 is connected.The servo unit 212 is configured to manipulate the IP 101 in multiple directions relative to the sewing head 230. The robotic arm 220, the sewing head 230, and the servo unit 212 may operate in concert with each other to perform sewing on the IP 101.

[0039] The servo unit 212 may include a gripping portion 2121 that is configured to grip the IP 101 without interfering with sewing operations and multiple servo arms 2122 that are movable and rotatable relative to the IP 101 and relative to each other. The gripping portion 2121 includes gripping members 2123 that can grip any portion of the IP 101 and can rotate relative to the proximal servo arm of the multiple servo arms 2122. The servo unit 212 is thus capable of moving and / or rotating the IP 101 in and about multiple directions and axes. That is, the servo unit 212 can move the IP 101 upwards and downward, forward and backward, laterally and / or around any vertical or horizontal axis.

[0040] The sewing head 230 comprises a sewing needle 231 and a needle plate 232. The robotic arm 220 comprises the sewing head 230, an optional base 221 which can be anchored to the base portion 211 of the support 210 (as indicated above, in the case of a robotic gantry system for example or in other similar cases, the optional base 221 is not present and no anchoring is necessary or provided), a first arm 222 which can rotate in at least one direction, a second arm 223 which is rotatably attached to the first arm 222 to be able to rotate in at least one direction, and a coupling 224 by which the sewing head 230 is rotatably attached to the second arm 223 to be able to rotate in at least two directions.The support 210 includes the optional base portion 211, the servo unit 212 and further includes a frame 213 to which the optional base portion 211 and the servo unit 212 are attached at a distance from each other, and a vertically oriented screen 214 which is supported on the frame 213 proximate to the servo unit 212.

[0041] The servo unit 212 is configured to manipulate the IP 101 in multiple directions relative to the sewing head 230 during sewing. More particularly, the servo unit 212 is configured to rotate and translate the IP 101 about and along multiple axes during sewing. That is, the servo unit 212 is configured to rotate the IP 101 about a longitudinal axis A1 of the IP 101, to raise and lower the IP 101 along a vertical axis A2, and to drive the IP laterally in first and second transverse directions along lateral directions A3 and A4 during sewing. Thus, as discussed further, stitching may be performed along multiple exterior and bottom faces of the IP 101 at the elongated flattened section 110, the elongated curved section 120, and one or more of the vents 121.

[0042] With continued reference to [Fig. 1] and [Fig. 2A] and 2B and with further reference to [Fig. 3], the robotic sewing assembly 201 may further comprise a programmable logic controller 301. The programmable logic controller 301 may comprise a processor 310, a memory unit 320 and a servo control unit 330 which is disposed in signal communication with the robotic arm 220, the sewing head 230 and the servo unit 212. The memory unit 320 has executable instructions stored thereon which may be read and executed by the processor 310. When the executable instructions are read and executed by the processor 310, the processor 310 effectively controls the robotic arm 220, the sewing head 230 and the servo unit 212 via the servo control unit 330 to that they work in concert with each other in order to perform sewing on the IP 101 without operator intervention.

[0043] With continued reference to [Fig. 1] through [Fig. 3] and with further reference to [Fig. 4], a sequence 400 of the operations of the robotic arm 220, the sewing head 230, and the servo unit 212 is shown. As shown in images (1) and (2) of [Fig. 4], the robotic arm 220 initially extends the sewing head 230 toward and over the IP 101 while slightly rotating the sewing head 230. As shown in images (3), (4), and (5) of [Fig. 4], the rotation of the sewing head 230 continues, and the servo unit 212 begins rotating the IP 101 counterclockwise so that a bottom face of the IP 101 faces toward the sewing head 230. As shown in images (4) and (5) of [Fig.4], the robotic arm 220 then rotates the sewing head 230 downwardly and curvilinearly toward the IP 101 while the servo unit 212 rotates the IP 101 clockwise so that an edge of the IP 101 at a vent 121 is brought between the sewing needle 231 and the needle plate 232. At this point, as shown in images (6), (7), (8) and (9) of [Fig. 4], the robotic arm 220 drives the sewing head 230 laterally while the servo unit rotates the IP 101 counterclockwise so that the sewing head can apply stitches to the edge of the IP 101 at the vent 121. As shown in images (10) and (11) of [Fig.4], the robotic arm 220 then rotates the sewing head around the IP 101 to allow the sewing head to continue applying the stitches to the IP 101. As shown in image (12) of [Fig.4], this process continues until the sewing is complete after which the robotic arm 220 begins to pull the sewing head 230 away from the IP 101. .

[0044] With reference to [Fig. 5], a method 500 of operating a robotic sewing assembly for sewing an article, such as an instrument panel (IP), generally as described above with reference to [Fig. 1] to 4, is provided. The method 500 is executable by a programmable logic controller without operator intervention. As shown in [Fig. 5], the method 500 optionally comprises anchoring a robotic arm comprising a sewing head to a base portion of a support and / or providing the robotic arm comprising the sewing head and providing the support (block 501), connecting a servo unit of the support to the IP (block 502), and sewing along multiple exterior and bottom faces of the IP (block 503).The sewing of block 503 simultaneously includes controlling the robotic arm to manipulate the sewing head relative to the IP (block 5031), controlling the sewing head to apply stitches to the IP (block 5032), and controlling the servo unit to rotate the IP about a longitudinal axis of the IP, to raise and lower the IP, and to drive the IP laterally in first and second transverse directions (block 5033). Thus, when the IP includes an elongated flattened section, an elongated curved section, and one or more vents, the sewing of block 503 may . be executed along multiple exterior and lower faces of the IP at least at the elongated flattened section, the elongated curved section and the one or more vents.

[0045] The technical effects and advantages of the present disclosure lie in providing a support for a robotic sewing assembly which is capable of adjusting the position and / or orientation of a part or article being sewn relative to the sewing head of the robotic sewing assembly. The complete production of the part or article can thus be carried out more quickly and efficiently.

[0046] The term "approximately" is intended to include the degree of error associated with the measurement of the particular quantity based on the equipment available at the time the application is filed. For example, "approximately" may include a range of ±8%, 5%, or 2% of a given value.

[0047] Although the present disclosure has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and that certain of its elements may be substituted by equivalents without departing from the scope of the present disclosure. Furthermore, numerous modifications may be made to adapt a particular situation or a particular material to the teachings of the present disclosure without departing from the essential scope thereof. Accordingly, it is intended that the present disclosure is not limited to the particular embodiment disclosed as the best mode contemplated for carrying out the present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims.

Claims

Claims

1. A robotic sewing assembly (201), comprising: a support (210) for supporting an article (101) being sewn; and a robotic arm (220) comprising a sewing head (230), the sewing head (230) being configured to apply stitches to the article (101) and the robotic arm (220) being configured to manipulate the sewing head (230) in multiple directions relative to the article (101), the support (210) comprising a servo unit (212) to which the article (101) is connected and which is configured to manipulate the article (101) in multiple directions relative to the sewing head (230), and the robotic arm (220), the sewing head (230) and the servo unit (212) being operable in concert.

2. The robotic sewing assembly of claim 1, wherein the robotic arm (220) comprises: a first arm (222) rotatable in at least one direction; a second arm (223) rotatably attached to the first arm (222) to be rotatable in at least one direction; and a coupling (224) by which the sewing head (230) is rotatably attached to the second arm (223) to be rotatable in at least two directions.

3. A robotic sewing assembly according to claim 1, wherein the sewing head (230) comprises a sewing needle (231) and a needle plate (232).

4. The robotic sewing assembly of claim 1, wherein the support (210) further comprises: a frame (213) on which the servo unit (212) is fixed; and a vertically oriented screen plate (214) supported on the frame (213) proximate the servo unit (212).

5. The robotic sewing assembly of claim 1, wherein the servo unit (212) is configured to manipulate the article (101) in multiple directions relative to the sewing head (230) during sewing.

6. The robotic sewing assembly of claim 1, wherein the servo unit (212) is configured to rotate and translate the article (101) about and along multiple axes.

7. The robotic sewing assembly of claim 1, wherein the servo unit (212) is configured to rotate the article (101) about a longitudinal axis (Al) of the article (101), to raise and lower the article (101), and to drive the article (101) laterally in first and second transverse directions.

8. The robotic sewing assembly of claim 1, further comprising a programmable logic controller for controlling the robotic arm (220), the sewing head (230) and the servo unit (212) to operate in concert with each other and without operator intervention.

9. A robotic sewing assembly for sewing a dashboard - IP- (101) comprising an elongated flattened section (110) and an elongated curved section (120) defining vents (121), the robotic sewing assembly (201) comprising: a support (210) for supporting the IP (101);and a robotic arm (220) comprising a sewing head (230), the sewing head (230) being configured to apply stitches to the IP (101) and the robotic arm (220) being configured to manipulate the sewing head (230) in multiple directions relative to the IP (101), the holder (210) comprising a servo unit (212) to which the IP (101) is connected and which is configured to manipulate the IP (101) in multiple directions relative to the sewing head (230), and the robotic arm (220), the sewing head (230) and the servo unit (212) being operable in concert to perform sewing on the elongated flattened section (110) and the elongated curved section (120) defining the vents (121) of the IP (101).;

10. The robotic sewing assembly of claim 9, wherein the robotic arm (220) comprises: a first arm (222) rotatable in at least one direction; a second arm (223) rotatably attached to the first arm (222) to be rotatable in at least one direction; and a coupling (224) by which the sewing head (230) is rotatably attached to the second arm (223) to be rotatable in at least two directions.

11. A robotic sewing assembly according to claim 9, wherein the sewing head (230) comprises a sewing needle (231) and a needle plate (232).

12. The robotic sewing assembly of claim 9, wherein the support (210) further comprises: a frame (213) on which the servo unit (212) is fixed; and a vertically oriented screen plate (214) supported on the frame (213) proximate the servo unit (212).

13. The robotic sewing assembly of claim 9, wherein the servo unit (212) is configured to manipulate the IP (101) in multiple directions relative to the sewing head (230) during sewing.

14. The robotic sewing assembly of claim 9, wherein the servo unit (212) is configured to rotate and translate the IP (101) around and along multiple axes during sewing.

15. A robotic sewing assembly according to claim 9, wherein the servo unit (212) is configured to rotate the IP (101) about a longitudinal axis (Al) of the article (101), to raise and lower the IP (101) and to drive the IP (101) laterally in first and second transverse directions during sewing.

16. The robotic sewing assembly of claim 9, wherein sewing is performed along multiple outer and lower faces of the IP (101) at the elongated flattened section (110), the elongated curved section (120), and one or more of the vents (121).

17. The robotic sewing assembly of claim 9, further comprising a programmable logic controller (301) for controlling the robotic arm (220), the sewing head (230) and the servo unit (212) to operate in concert with each other to perform sewing on the elongated flattened section (110) and the elongated curved section (120) defining the vents (121) of the IP (101) and without operator intervention.

18. A method (500) of operating a robotic sewing assembly (201) for sewing an article (101), the method comprising: providing a robotic arm (220) comprising a sewing head (230) and providing a support (210); connecting a servo unit (212) of the support (210) to the article (101); and sewing along multiple exterior and bottom faces of the article (101), the sewing simultaneously comprising: controlling the robotic arm (220) to manipulate the sewing head (230) relative to the article (101); controlling the sewing head (230) to apply stitches to the article (101); and controlling the servo unit (212) to rotate the article (101) about a longitudinal axis (A1) of the article (101), to raise and lower the article (101) and to drive the article (101) laterally in first and second transverse directions.

19. The method of claim 18, wherein the method is executable by a programmable logic controller (301) without operator intervention.

20. The method of claim 18, wherein: the article (101) is an instrument panel (IP) of an automobile and comprises an elongated flattened section (110) and an elongated curved section (120) defining one or more vents (121); and the stitching is performed along multiple exterior and lower faces of the IP at the elongated flattened section (110), the elongated curved section (120) and the one or more vents (121).

Images