Manufacturing device of skin with stitch and manufacturing method

Abstract

To suppress positional deviation in stitches in a skin.SOLUTION: A manufacturing device of skin with stitch includes: a skin receiving jig 1 having a three-dimensional-shaped receiving surface 7 for receiving a three-dimensional-shaped skin 40, and a fixing device (adsorption device) for fixing the skin 40 which the receiving surface 7 has received; a sewing machine 20 for sewing stitches on the skin 40; a robot 30 for taking out the skin from the skin receiving jig 1, moving it to the sewing machine 20 and feed-driving it; and a control device for controlling the sewing machine 20 and the robot 30.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an apparatus and method for producing a sewn stitched skin for use as a skin for a substrate. [Background technology]

[0002] In recent years, decorative stitching has become common in automobile interior parts (e.g., door interior parts, instrument panels, consoles, etc.) to improve the quality of their appearance. Interior parts are thick, so it is difficult to sew across their entire thickness. Therefore, interior parts are made by joining a skin with sewn stitching to a base material made of resin.

[0003] There are two methods for manufacturing stitched skins: one in which a sewing worker sews together multiple cut two-dimensional (flat) skins into one three-dimensional shape using a sewing machine, and another in which a sewing worker hand-sews three-dimensional stitches onto skin that has been three-dimensionally shaped by resin molding. However, with these manual methods, the skill level of the sewing worker affects the quality and sewing speed, which can lead to variations in quality, defect rate, production volume, etc. depending on the worker. Also, it takes time to master sewing skills.

[0004] In view of this, an apparatus and method have been devised for automatically sewing stitches onto a three-dimensionally shaped skin using a robot and a sewing machine.

[0005] Patent Document 1 describes an automatic sewing system that includes a work table that sets a three-dimensionally shaped skin in a predetermined position, a robot equipped with a suction pad that holds the skin, an automatic sewing machine, and a control unit that controls the robot and the automatic sewing machine. The robot takes the skin from the work table and places it on the hook stand of the automatic sewing machine, and the automatic sewing machine forms decorative stitches on the skin moved by the robot.

[0006] Patent Document 2 describes a sewing system that includes a robot arm having a jig that holds at least the sewing line portion of the skin in a stretched state, a sewing machine, and a control unit that controls the robot arm and the sewing machine motor. The robot arm moves the jig relative to the fixed sewing machine, and the sewing machine forms stitches along the sewing line of the skin.

[0007] According to the devices and methods described in Patent Documents 1 and 2, instead of a sewing worker, a robot fixes and transports the skin and sews stitches in conjunction with the sewing machine. The sewing worker only needs to set the skin in the designated position and start it, so no sewing skills are required and labor savings can be expected. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] JP2018-068696A [Patent Document 2] JP 2018-171325 A Summary of the Invention [Problem to be solved by the invention]

[0009] The quality standards and positional tolerances for the stitching parts of the skin are strictly stipulated in the product drawings. However, the skin material is soft, such as polyvinyl chloride (PVC), olefin-based elastomer (TPO), and expanded polypropylene (PP), and in the actual manufacturing process, the product dimensional accuracy and deformation are easily affected by the environmental temperature and humidity of the production site in addition to the processing conditions, which adversely affects the positional accuracy of the stitching. Even if the product is manufactured in the exact same environment, the skin may deform or shift in the setting position depending on the way the skin is fixed and held and the posture, which may cause the stitching to shift in position.

[0010] In the devices and methods described in Patent Documents 1 and 2, the operations such as skin transportation are performed by a robot and are therefore stable, but if even a slight deformation or misalignment occurs in the skin before transportation or at the moment the robot takes it out, this deformation or misalignment will directly lead to misalignment of the stitches, reducing the appearance quality (as the robot simply moves according to a program). As shown in Figure 11, misalignment of stitches can include variations in sewing pitch, variations in the length of each stitch, and lateral variations.

[0011] Therefore, it is extremely important to prevent even slight deformation of the skin or misalignment of the setting position in the skin receiving jig. However, there are no prior art examples in which these issues have been fully considered.

[0012] SUMMARY OF THE PRESENT EMBODIMENT An object of the present invention is to prevent the displacement of stitches on the surface of a skin. [Means for solving the problem]

[0013] [1] A skin receiving jig having a three-dimensional receiving surface for receiving a three-dimensional skin and a fixing device for fixing the skin received by the receiving surface; A sewing machine to sew stitches on the surface of the leather, A robot that removes the skin from the skin receiving jig, moves it to the sewing machine and drives it to feed. An apparatus for manufacturing stitched skins, comprising a sewing machine and a control device for controlling a robot.

[0014] [2] The manufacturing apparatus for stitched skin according to [1] or [2], wherein the fixing device is an adsorption device that adsorbs multiple points of the skin.

[0015] [3] The manufacturing apparatus for stitched skin according to [1] or [2], further comprising a position deviation detection device for detecting a position deviation of the skin received by the receiving surface relative to a reference position on the receiving surface.

[0016] [4] The apparatus for manufacturing stitched skins according to any one of [1] to [3], wherein the position deviation detection device uses a camera provided on the skin receiving jig.

[0017] [5] The apparatus for manufacturing stitched skin according to any one of [1] to [4], wherein the position deviation detection device performs image recognition on a plurality of characteristic parts of the skin imaged by the camera.

[0018] [6] The apparatus for manufacturing stitched skins according to any one of [1] to [5], wherein the control device does not operate the robot and the sewing machine when the position deviation detection device detects a position deviation greater than a set value.

[0019] [7] The device for manufacturing stitched skins described in any one of [1] to [5], wherein the control device reflects the positional deviation detected by the positional deviation detection device in the sewing program (such as by correcting the trajectory (track) of the skin by the robot).

[0020] [8] The apparatus for manufacturing stitched skins according to any one of [1] to [7], wherein the receiving surface of the skin receiving jig is made of metal.

[0021] [9] The apparatus for manufacturing stitched skins according to any one of [1] to [7], wherein the receiving surface of the skin receiving jig is made of resin.

[0022]

[10] Manufacturing method for stitched skin The three-dimensional skin is supported on a three-dimensional support surface of a skin support jig, and the skin supported by the support surface is fixed by a fixing device of the skin support jig; The robot removes the skin from the skin receiving jig, moves it to the sewing machine, and drives it to feed. A method for manufacturing a stitched skin, in which a sewing machine sews stitches into the skin.

[0023] <effect> Not only is the three-dimensional skin received by the three-dimensional receiving surface of the skin receiving jig, but the skin received by the receiving surface is fixed by a fixing device, so that displacement is suppressed. Effect of the Invention

[0024] According to the present invention, it is possible to suppress misalignment of stitches on the surface of the skin. [Brief description of the drawings]

[0025] [Figure 1] FIG. 1 shows an apparatus for manufacturing stitched skins according to an embodiment of the present invention, and is a perspective view of the state when a robot removes a skin from a skin receiving jig. [Diagram 2] FIG. 2 shows the same skin, (a) being a perspective view and (b) being a plan view. [Diagram 3] FIG. 3 shows the same skin receiving jig, (a) being a perspective view and (b) being a plan view. [Figure 4] 4 shows the same skin receiving jig, where (a) is a sectional view taken along line IVa-IVa in FIG. 3, and (b) is a plan view taken along line IVb-IVb in FIG. [Diagram 5] Figure 5 shows examples of feature images recognized by the skin support jig. (a) is a schematic diagram of a stitch groove, (b) is a logo, (c) is a mold number and a grain pattern boundary, (d) is a marking line, (e) is a simple hole mark, (f) is an air blow hole mark, and (g) is an unevenness. [Figure 6] 6(a) and (b) are flow charts showing two examples of the manufacturing process of the skin receiving jig. [Figure 7] FIG. 7 shows a sewing process, where (a) is a flow chart of Example 1, (b) is a flow chart of Example 2, and (c) is a flow chart of Example 3. [Figure 8] FIG. 8 shows the manufacturing apparatus for stitched skin, and is a perspective view of the skin being placed against the sewing machine by the robot and driven to feed the skin, and the sewing machine sewing stitches onto the skin. [Figure 9] FIG. 9 shows the manufacturing apparatus for stitched skin, and is a perspective view of the robot moving the stitched skin from the sewing machine to the stocker. [Figure 10] FIG. 10 is a perspective view of the stitched skin (with unnecessary parts trimmed). [Figure 11] 11(a) and (b) are explanatory diagrams for explaining the positional deviation of stitches on the surface of the skin. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] 1. Epidermis The material for the skin is not particularly limited, but examples include resin, elastomer, rubber, and the like. Examples of methods for producing the skin include slush molding, vacuum molding (convex drawing, concave drawing), spray molding, and the like. The thickness of the skin is not particularly limited, but may be, for example, 1 to 4 mm.

[0027] The thickness of the thread forming the stitches is not particularly limited, but is preferably 0.3 to 1.5 mm. Stitch lines include single stitch (1 line) and double stitch (2 lines). The stitches may be formed in the shallow grooves (design grooves) of the skin, or may be formed on the surface without the shallow grooves.

[0028] The use of the skin is not particularly limited, but an example of the use is bonding to a resin base material of an automobile interior part (for example, an interior door panel, an instrument panel, a console, a glove box, etc.).

[0029] 2. Covering jig The skin receiving jig may have a receiving portion including a receiving surface formed of metal or resin. An example of the metal is aluminum alloy. The resin may be glass fiber-reinforced resin. The hardness of the receiving portion is not particularly limited, but is preferably HBW45-50 in the case of an aluminum alloy, and R100-140 in the case of a resin.

[0030] Examples of manufacturing processes for the skin receiving jig body include a process in which an unfinished skin receiving jig is cast using a mold and the surface of the unfinished product is NC machined to turn it into a skin receiving jig, and a process in which a steel block is NC machined to turn it into a skin receiving jig. The dimensional accuracy of the NC processing is not particularly limited, but is preferably within ±0.2 mm, more preferably within ±0.1 mm, and most preferably within ±0.05 mm. The NC processed surface roughness is not particularly limited, but is preferably within ±0.05 mm, more preferably within ±0.02 mm, and most preferably within ±0.002 mm.

[0031] The setting position accuracy (setting value) of the skin is not particularly limited, but is preferably within ±1.0 mm, more preferably within ±0.3 mm, and most preferably within ±0.1 mm.

[0032] 3.Fixing device The fixing device is not particularly limited, but examples thereof include an adsorption device, a pressure type device using a plunger (spring) or the like, and a physical type device such as a clamp. The suction device can be, for example, one that includes a suction pad facing the receiving surface and a pressure reducing device connected to the suction pad. The material of the suction pad is not particularly limited, but examples include soft materials such as silicone, elastomer, and rubber. The diameter of the suction pad is not particularly limited, but is preferably 10 to 50 mm, and pads with different diameters may be used depending on the site. It is preferable to provide a plurality of suction pads in order to suction multiple points of the epidermis. The pitch between the suction pads is not particularly limited, but is preferably 150 to 400 mm. It is preferable to provide suction pads preferentially in the recesses of the receiving surface surrounded by vertical walls, since this makes it easier to improve positioning accuracy (within 150 mm of the wall).

[0033] 4. Position deviation detection device The positional deviation detection device is not particularly limited, but examples include a device that recognizes the shape of multiple characteristic parts of the epidermis captured by a camera, and a device that recognizes the color of the captured image, shadows, etc. EXAMPLES

[0034] Hereinafter, specific examples of the present invention will be described with reference to Figures 1 to 10. Note that the materials, configurations, and numerical values ​​described in the examples are merely examples and can be changed as appropriate.

[0035] The skin 40 onto which the stitches are sewn in this embodiment is a three-dimensional skin curved in an arch shape in the length direction and also curved convexly in the width direction at the center, for joining to a base material (not shown) of an automobile door interior (door upper panel). This skin 40 is resin molded with a flange 42 as shown in Fig. 2, and after a decorative stitch 41 is sewn in the width direction center in this embodiment, the flange 42 is cut off as shown in Fig. 10.

[0036] <Stitched skin manufacturing equipment> The stitched skin manufacturing apparatus of the embodiment is as follows: A skin receiving jig 1 including a three-dimensional receiving surface 7 for receiving a three-dimensional skin 40 and a fixing device for fixing the skin received by the receiving surface 7; A sewing machine 20 for sewing stitches 41 onto a surface 40; A robot 30 which takes out the skin 40 from the skin receiving jig 1, moves it to the sewing machine 20 and drives it to feed; The sewing machine 20 and the robot 30 are controlled by a control device. Each part is described in detail below.

[0037] The skin receiving jig 1 includes a base 2, a support leg 3 erected on the base 2, a support stand 4 on the support leg 3, a skin receiving jig main body 5 including a receiving surface 7 supported by the support stand 4, a fixing device (suction device 10) provided on the skin receiving jig main body 5, and a position deviation detection device 15 provided on the skin receiving jig main body 5.

[0038] The skin receiving jig body 5 comprises a receiving portion 6 including a receiving surface 7 on its upper surface, and a side wall portion 8 and a reinforcing wall portion 9 which support the receiving portion 6, and is made of an aluminum alloy. The receiving surface 7 is formed with high precision into the same three-dimensional shape as the three-dimensional shape of the skin.

[0039] The fixing device is an adsorption device 10 that adsorbs the epidermis at multiple points. As shown in Fig. 3 and Fig. 4(a), the suction device 10 comprises a suction pad 11 made of a flexible material that is inserted into a mounting hole 12 formed in the receiving portion 6 and faces the receiving surface 7, and a pressure reducing device (not shown) connected to the suction pad 11. In this example, four suction pads 11 are provided near the left and right ends and in the middle thereof at a pitch of 150 to 400 mm. As shown on the leftmost side in Fig. 3(a), the suction pads 11 are preferentially provided in a recess 13 surrounded by a vertical wall on the receiving surface 7, since it is easy to improve positioning accuracy.

[0040] The positional deviation detection device 15 detects the positional deviation of the skin 40 received by the receiving surface 7 relative to a reference position on the receiving surface 7, and as shown in Figures 3(b) and 4(b), is made up of a camera 16 attached below a through hole 17 formed in the receiving part 6, and an image recognition device (not shown) that recognizes images of multiple characteristic parts of the skin captured by the camera 16. In this example, two cameras 16 are provided near the left and right ends.

[0041] The camera 16 performs image recognition of characteristic parts of the skin. The characteristic parts may be any parts that can be optically recognized as an image, and are not particularly limited, but examples thereof include (a) design grooves of stitching lines, (b) airbag logo marks and design lines, (c) mold numbers, characters, boundary lines between textured and non-textured surfaces, (d) marking lines, (e) normal holes, (f) slits for air blow holes, and (g) uneven shapes on the skin, as shown in Fig. 5.

[0042] The image recognition device recognizes characteristic parts of the image captured by the camera 16 and compares it with a master image and an image of the previous workpiece, thereby optically measuring the amount of positional deviation and orientation (direction) deviation of the current workpiece.

[0043] A manufacturing process of the skin receiving jig body 5 configured as above will be exemplified below. As shown in Figure 6(a), the process involves creating CAD data, casting a body slightly larger than the skin support jig body 5 using aluminum alloy, cast iron, etc., NC machining the surface of the casting based on the CAD data to finish it into the skin support jig body 5, assembling the components (suction device 10, camera 16, etc.), and checking the setting position accuracy and function of the skin shape. As shown in Figure 6(b), the process involves creating CAD data, procuring and obtaining a metal block made of aluminum alloy, cast iron, etc., NC machining the metal block based on the CAD data to make the skin support jig body 5, assembling the components (suction device 10, camera 16, etc.), and checking the setting position accuracy and function of the skin shape. The hardness of the skin receiving jig body 5, the NC processing dimensional accuracy, the NC processing surface roughness, and the setting position accuracy (setting value) of the skin are as described above.

[0044] 1, the sewing machine 20 is provided with a sewing machine bed 21 having a shuttle and its drive mechanism, a sewing machine arm 22 having a needle and its drive mechanism, and a support part 23 that supports the sewing machine arm 22 relative to the sewing machine bed 21, and is formed in a generally U-shape when viewed from the front. The sewing machine 20 may also be provided with a feed mechanism 24 that feeds the cover in one direction.

[0045] 1, 8 and 9, the robot 30 is a general-purpose vertical articulated type product, and includes a plurality of arms 31, a skin removal part 32 attached to the arm 31 at the tip, and a plurality of suction removal pads 33 provided on the skin removal part 32. A pressure reducing device (not shown) is connected to the suction removal pads 33.

[0046] The control device is configured to include a computing device, a storage device, and an interface, and is programmed to control the sewing machine 20 and the robot 30 as in the following embodiment 1, 2, or 3.

[0047] <Method of manufacturing stitched skin> Example 1 Basically, the three-dimensionally shaped skin 40 is received on the three-dimensionally shaped receiving surface 7 of the skin receiving jig 1, the skin 40 received by the receiving surface 7 is fixed by a fixing device of the skin receiving jig 1, the robot 30 removes the skin 40 from the skin receiving jig 1 and moves it to the sewing machine 20, which drives and feeds it, and the sewing machine 20 sews stitches 41 on the skin 40. Specifically, the process proceeds as follows, following the flow chart in FIG. (1) An operator sets the skin 40 on the skin receiving jig 1 and fixes the skin 40 in position with a fixing device. Specifically, the skin 40 (or the flange 42) is fixed by suction with the suction pad 11. (2) Operator initiated (automatic cycle start) (3 Camera 16 is not used in this example) (4) The control device causes the skin removal section 32 of the robot 30 to approach the skin 40 on the skin receiving jig 1, the suction removal pad 33 adsorbs the skin 40, the suction pad 11 of the skin receiving jig 1 releases the suction, the robot 30 removes the skin 40 (see FIG. 1), moves it between the needle and the shuttle of the sewing machine 20 and performs the feed drive for sewing (see FIG. 8), and the sewing machine 20 sews a stitch 41 on the skin 40 (robot 30 sewing). (5) The control device causes the sewing machine 20 to perform thread trimming after sewing (automatic). (6) The control device causes the robot 30 to move the stitched skin 40 to the stocker 50 (see FIG. 9), and the suction / removal pad 33 releases the suction (automatic). (7) Inspection by workers (quality check)

[0048] According to the first embodiment, not only is the three-dimensional skin 40 received by the three-dimensional receiving surface 7 of the skin receiving jig 1, but the skin 40 received by the receiving surface 7 is fixed by a fixing device, so that deformation or misalignment of the set position of the skin 40 before transportation or at the moment when the robot 30 takes it out is unlikely to occur. Therefore, misalignment of stitches due to the deformation or misalignment of the set position is suppressed, and the appearance quality is maintained.

[0049] Example 2 As shown in the flow chart of FIG. 7(b), the second embodiment differs from the first embodiment only in that a positional deviation detection device 15 is used, and when the positional deviation detection device 15 detects a positional deviation larger than a set value, the control device does not operate the robot 30 and the sewing machine 20. The rest of the second embodiment is the same as the first embodiment.

[0050] According to the second embodiment, even if a positional deviation larger than a set value occurs, the robot 30 and the sewing machine 20 are not operated (an alarm may be sounded at this time), and the worker can reset the skin on the skin receiving jig 1.

[0051] Example 3 As shown in the flow chart of FIG. 7(c), the third embodiment differs from the first embodiment only in that a positional deviation detection device 15 is used and the positional deviation detected by the positional deviation detection device 15 is reflected in the sewing program by the control device. The rest of the third embodiment is the same as the first embodiment.

[0052] According to the third embodiment, even if a positional deviation larger than the set value occurs, the control device reflects the positional deviation in the sewing program, so that sewing by the robot 30 proceeds and positional deviation of stitches is suppressed without the operator having to reset the program as in the second embodiment.

[0053] The present invention is not limited to the above-described embodiment, and can be embodied by making appropriate modifications without departing from the gist of the invention. [Explanation of symbols]

[0054] 1 Surface support jig 5 Surface receiving jig body 6 Receiving part 7 Receiving surface 10 Adsorption device 11 Suction pad 12 Mounting hole 15 Detection device 16 Cameras 17 Through hole 20 Sewing Machine 30. Robot 31 Arm 32 Epidermis extraction part 33 Suction removal pad 40 Epidermis 41 Stitches 42 Flange

Claims

1. a skin receiving jig including a three-dimensional receiving surface for receiving a three-dimensional skin and a fixing device for fixing the skin received by the receiving surface; A sewing machine to sew stitches on the surface of the leather, A robot that removes the skin from the skin receiving jig, moves it to the sewing machine and drives it to feed. An apparatus for manufacturing stitched skins, comprising: a sewing machine; and a control device for controlling a robot.

2. 2. An apparatus for manufacturing stitched skins according to claim 1, wherein the fixing device is a suction device for suctioning a plurality of points of the skin.

3. 2. The apparatus for manufacturing stitched skins according to claim 1, further comprising a positional deviation detection device for detecting a positional deviation of the skin received by the receiving surface with respect to a reference position on the receiving surface.

4. 2. An apparatus for manufacturing stitched skins according to claim 1, wherein said positional deviation detection device is a camera provided on said skin receiving jig.

5. 2. The apparatus for manufacturing stitched skins according to claim 1, wherein the positional deviation detection device performs image recognition of a plurality of characteristic portions of the skin imaged by the camera.

6. 2. An apparatus for manufacturing stitched skins according to claim 1, wherein the control device does not operate the robot and the sewing machine when the position deviation detection device detects a position deviation larger than a set value.

7. 2. An apparatus for manufacturing stitched skins according to claim 1, wherein said control device reflects the positional deviation detected by said positional deviation detection device in a sewing program.

8. 2. An apparatus for manufacturing stitched skins according to claim 1, wherein the receiving surface of the skin receiving jig is made of metal.

9. 2. An apparatus for manufacturing stitched skins according to claim 1, wherein the receiving surface of the skin receiving jig is made of resin.

10. The three-dimensional skin is supported on a three-dimensional support surface of a skin support jig, and the skin supported by the support surface is fixed by a fixing device of the skin support jig; The robot removes the skin from the skin receiving jig, moves it to the sewing machine, and drives it to feed. A method for manufacturing a stitched skin, in which a sewing machine sews stitches into the skin.

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